The Thomas build has been challenging. We have not been able to find any schematics as we did with the Protos. But, we have a wealth of photo evidence, and two commercially available models. As well, we had wonderful help from Denise Sims at the NAM in Reno.
One of the most difficult questions was “what did the car look like at the beginning of the race?” Most of the archival pictures were of the front end of the cars. But, we lucked out and were able to blow up a photo from our collection to actually see what the rear end of the car looked like, albeit from a “birds eye view.” And a German source was able to provide a picture of the Thomas in a garage just prior to the start of the race.
The chassis work was designed by Noel at Wadson’s in Edmonton. Using a number of references (including statistics from the NAM in Reno, models, and several hundred photos) Noel was able to design the chassis in the computer. A good deal of computer design was also used to fabricate the rear spring hangers as well as the radiator shell etc.
The steel cowl has been made out of three pieces of metal, bent to the shape of the original Thomas. The radiator shell (which has not been cutout yet) will soon don the famous Thomas Flyer signature as part of the shell, which will then be brassed.
The fenders are being rolled now. The most difficult part here will be adding the beading which Randy Kvill of the Reynolds Museum pointed out would be how most of the fenders from this era were made.
The rear end of the Thomas has also had to have custom axles created that will be able to take the chain-drive. It will be a working chain; although not powered by the engine but rather by the actual axles, Wayne Wadson was very concerned about the safety of the chains. After all, filmmakers are not racecar drivers. To that end he will be adding “safety housings” for the chains themselves, which will be in place all the time unless the car is being filmed in front of the cameras.
Wheel Build:
The Thomas Flyer, Protos, Zust, and de Dion wheels are being created by master wheelwright Dale Anderson. Using steel rims from a variety of sources, the wood needs to be steamed and bent into the correct arc for each size rim and then carefully dried so as not to crack the wood. Too much pressure or too fast a drying process can render these wheels brittle and dangerous. But, when executed by a master like Dale, you end up with beautiful wheels of the correct vintage.
The hubs for the wheels are also being custom made. Designed by a collaboration of all three fabricators on this project, the final working drawings and actual machining fell to Stamco in Edmonton, Alberta. A two piece steel system will lock the wooden spokes to the felloes and the hub, ensuring a tight perfect fit.
One of the challenges was trying to get the hub size as close as possible to the 1907 size of approximately 9 inches yet still have enough room for a Ford bolt pattern on disc brakes. We think we have succeeded.
The Thomas Flyer has the skeleton of its seats in place. The boys at Wadson’s need to do this in order to properly set the steering wheels and pedals. There is only so much you can do from photos. Sometimes a test fit is in order. The shroud for the rad is in place but the centre has not yet been cut for the core.
The Thomas from a side view. You can see the beginnings of the inner fender supports. The hood will now be sent away to have the louvers punched in them.
January 19, 2007: New photos
May 15, 2007
With the coachwork completed by Shelmar Construction and the wheels delivered by Dale Anderson, the Thomas looked just as it did 99 years ago when it rolled off the rail car and into the New York Times main floor lobby. With authentic period shovels, picks, rope, more than 100 leather buckle straps, and a roped steering wheel … the Thomas went before the cameras March 24, 2007. Now, on to the summer shooting!
One of the most difficult questions was “what did the car look like at the beginning of the race?” Most of the archival pictures were of the front end of the cars. But, we lucked out and were able to blow up a photo from our collection to actually see what the rear end of the car looked like, albeit from a “birds eye view.” And a German source was able to provide a picture of the Thomas in a garage just prior to the start of the race.
The hubs for the wheels are also being custom made. Designed by a collaboration of all three fabricators on this project, the final working drawings and actual machining fell to Stamco in Edmonton, Alberta. A two piece steel system will lock the wooden spokes to the felloes and the hub, ensuring a tight perfect fit. 
The Thomas Flyer has the skeleton of its seats in place. The boys at Wadson’s need to do this in order to properly set the steering wheels and pedals. There is only so much you can do from photos. Sometimes a test fit is in order. The shroud for the rad is in place but the centre has not yet been cut for the core.
