New Cordite Build, with a twist.... - Page 25

slartibartfast · #**481** 14th May 2014, 20:02

Viatron
Sorry I missed this .... trust all is well.
Gwet well soon.
GB
Slarti

Mister Towed · #**482** 14th May 2014, 22:04

Quote:

Originally Posted by Viatron

Thanks Oxford and Paul, Towed hmmm don't think I can publish my reply on an open forum......:-)

Sorry, s'pose I should've added OUCH! Take it easy and get well soon.

oxford1360 · #**483** 15th May 2014, 06:38

I guess the moral of this story is, never use an angle grinder whilst naked.

Viatron · #**484** 15th May 2014, 10:05

Nah that's the scar on my left knee and the other one on my left index finger the one on my badger sack is far worse!

phil9 · #**485** 17th May 2014, 06:53

ouch get well soon .....

Viatron · #**486** 3rd June 2014, 20:33

And I'm back!
Spent the day in the workshop Saturday and with assistance from Dave and my mate Sean we got the passenger side ali panel in and also the panel on the outside of the drivers foot well. Totally forgot about pics I was so happy to be back in the workshop.
I'm on a project in Dudley for the next 6 weeks which is as close to home as I seem to get work these days so the plan is to spend 2 evenings a week in the workshop for just a couple of hours so that I can accelerate the build. Did my first stint tonight and managed to get 85% of the filler and fibreglass work done on the sides where the body meets the Ali panelling.
Started with this, I filled it before leaving on Saturday with bridging
filler:

a bit of a go with the Da using a 180 grit pad saw it looking like this:

Skim of normal filler

Filler all applied using my trusty silicone bakers scraper thingy, really flexible so good for curves and cleans up really easily. This ones about 5 years old now and still going strong.

A bot more sanding work had them looking like this:

Nice and straight

You can see here how the body now fits to the ali with no gap and the panel gives a good reference to sand to to get a straight edge.

A good couple of coats of primer filler:

TTFN
Mac

Paul L · #**487** 4th June 2014, 06:20

Mac - Great work, it always amazes me that you can go from such a rough starting point to such a smooth finish at the end.

Although I am still trying not to think about the "opportunities" to practise this sort of thing my body shell is going to give me.

Hope you get the chance to mix work with garage time.

Good luck, Paul.

mas123mas · #**488** 4th June 2014, 07:44

Mac, What make of bridging filler and top filler do you use?

Looking good

Viatron · #**489** 5th June 2014, 20:22

Mas, pictures below of what im using, both are a little sloppier than im used to but seem to be working really well especially the fibreglass filler as it being a little runnier makes it easier to get a smooth finish when applying it and less chance of voids.
HTH
Mac

Viatron · #**490** 5th June 2014, 20:27

So couple of hours up the workshop tonight as I managed to get away from site early. Managed to make a good template for the rear panel so it all fits nicely around the tunnel.
Rear panel is in place now and managed to get a good wedge of fibreglass filler in between the top of the panel and the body so that it will be a seamless join like the sides. Gardening tomorrow night but am up the man cave all day Saturday so am hoping to get the drivers side of the cockpit done and signed off including replacing the front of the bulkhead. fingers Crossed!

Oh and on the way home I popped into machine mart as the amount of dust im now generating is scary and invested in a non too expensive wet and dry shop vac.

TTFN
Mac

davecymru · #**491** 6th June 2014, 05:10

MAN-VAC!!! Nice

Mister Towed · #**492** 6th June 2014, 07:36

Just don't bend down too close to it...

http://www.youtube.com/watch?v=43NX-Y9eopo

Viatron · #**493** 6th June 2014, 09:46

That's just wrong!

Viatron · #**494** 7th June 2014, 17:00

Good progress today. Got the rear deck filling finished. The large rivets I used to attach the rear deck to my ali rear body mount pulled down a bit more than I wanted in places. I originally was going to leave the rivets exposed as a features but that's not an option now so some fiberglass filler last time left it like this:

10 minutes with some 180 grit on the DA saw it knocked back and looking ready for final filler.

Before I filled it I decided to tackle the rear corner panelling behind the passenger. I have used 2mm ali for all of the flat panels but 2mm isn't very easy to curve unless you have the right kit so just for the corners I have gone down to 1mm sheet. I forgot to tack pictures of the bottom support which was made of ali angle slit on the back edge so it will form a curve. I left the top over long so I could fill against it.

One mistake I had made previously was riveting the rear edge of the side panel, had to drill them all out so I could now rivet through both the corner panel and the side panel as one.

I riveting the edge to the rear of the side panel first then found that just by pressing in the middle of the panel it formed a really nice curve so quickly riveted the other side in and job done! much easier than I was expecting.

The gap between the top of the panel and the side of the body was to say the least not a tight fit but I never expected it to be.

Out with the trusty fibreglass filler again.

obviously in between I had trimmed the top back a bit.

a bit of sanding work and it looked much better.

Its still a little green but next time I'm up I will pilot drill and fix the top of the ali corner panel into the fibreglass using some stainless screws.

My original plan was to crack on and get the other corner panel done but I decided to stay in the area I was and tackle the hump.

Stay tuned for part 2....
TTFN

Mac

Viatron · #**495** 7th June 2014, 17:14

My original plan for the humps was to rivet them on and make a feature of the flange, ooh err snigger snigger. After looking at the aforementioned paart though the thickness wasn't as consistent as I would have liked and would have needed a ;lot of work to get it looking right and even then the end result may not have been as good as I hoped so decided to go with bonding them on. First stage was to trim the , ooh err missus, flange off and sand the sides down. before and after shot below. You can also see that prior to tackling this I did some final filler work to the rear deck.

Some careful marking and I had the position set. I bonded and riveted a piece of angle at the front then made up 3 inch right angle brackets to go along the side in a similar manner. The only reason I made these rather than use the angle I had used for the front is that the angle is very heavy gauge and I needed to be able to bend the mounting tabs in a bit to make a good flush fit with the interior of the hump. At this stage I got carried away and forgot to take pics. I will try and remember when I do hump 2.

End result is that it all went together very well. covered the mounting angles in PU then slide the hump over and drilled, countersank then riveted along the edge approx. every 2 to 3 inches. Used and extra long rivet to secure the tail of the hump. By the time I was finished it was absolutely rock solid and even though the PU hadn't set I could push the hump and the whole car rocked! Fitting the humps has also added massively to the rigidity of the rear deck. A bit more fibreglass filler after roughing up the sides of the hump and the corresponding area on the rear deck and it looked thus:-)

The filler work looks quite rough in the last pic but before I left and whilst it was still a bit green I added a second coat and used my silicon spreader to good effect and got a nice smooth transition between the hump and the rear deck, and then promptly forgot to take any pics as I was too busy congratulating myself on such a good job...doh!

Hopefully up again on Tuesday evening so more updates then.

TTFN

Mac

swifty · #**496** 7th June 2014, 19:54

Looking good Viatron, the filler around the edges make a difference to the over all look.

Are you going to paint the ally panels or leave as is?

Viatron · #**497** 7th June 2014, 20:53

Cheers Swifty, my original plan was to leave the Ali panelling bare but the more I see how easily it marks the more inclined I am to use the remaining 1/2 pack of bed liner I used on the floors and tunnel to do the interior panels, I just think it will result in a clean finish that is pretty much maintenance free.
TTFN
Mac