Nicks Sammio Build - take 2

[WorldClassAccident]

Respirator and goggles. the fan is just to blow the worse of the dust out of the garage and I use my air gun on the compressor to clear the rest off from time to time. I have seen the state that garages can get into if you don't keep the dust under control.

I need to get a proper sander though. The Black and Decker mouse sander works fine but I spend more time clearing or replacing the sandpaper than actually sanding it, plus velcro sanding pads are an expensive way to do it.

Most of the air powered ones I have seen are orbital which leaves me with fears of circular marks all over the body. Tribute had proper long rubber sanding sleds but the y were hand powered which leaves me with fear of hard work. I don't mind hand finishing but there is a lot of sanding and filling to be done first.

[WorldClassAccident]

Lots of time wasted today with the family doing picnics by the sea instead of sweating inside the garage. More progress pictures tomorrow including my special long bed hand sanding sled. Works a treat. Idea 'borrowed' from Tribute Automotive.

[Mister Towed]

Originally Posted by WorldClassAccident

my special long bed hand sanding sled.

I just googled that and got twenty nine million pages of porn...

[WorldClassAccident]

I just googled that and got twenty nine million pages of porn...

3rd picture, I am the bloke second on the right

[WorldClassAccident]

Measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once, measure twice, cut once

Okay, so the sides of the frame sit on the plastic edges of the door shut, not on top of the actual chassis.

what kind of pillock would cut the plastic away to let them sit flush on the chassis before realising there is a sodding great chassi beam stopping the frame from sitting properly.

Thanks for the explanation Gary and thanks for answering my calls and PMs quickly and clearly.

Top service so far for the whole process so far. Body delivered when promised despite me delaying on the deposit and asking for changed delivery dates. Help people when I turned up to collect the car a couple of hours early. Stupid questions answered promptly and clearly without any giggling at me.

thanks

[Nike55]

Ah, the joys of DIY car building....

Looking forward to next instalment...

(I'm learning a lot from this thread)

[WorldClassAccident]

I have made my first sheet of fibre glass.

I think I may have made it a bit harder or stronger than necessary. It was harder to cut than the stuff from Scimitar and the G46 and the Lotus door.

At least I know a bit more about what I am doing. Photos to follow when I get the extra fibre glass off my fingers.

[Mister Towed]

Ha ha. I had the same problem - the resin's stickier than a sticky thing with a special reason to be sticky. Worth the effort doing it yourself though.

[WorldClassAccident]

Lost my cable thingy to tie the camera to the computer.

Anyway, frame fitted. Bits of the body sanded but loads more to do.

Grey pipe lagging cut in half makes a great sanding sled.

Ho=nest labour is well overrated. Give me business consultancy and staff instead of hand sanding any day!

Still smiling though

[WorldClassAccident]

Brake Servo is mounted on the bit above the front suspension and fouls the bonnet. I haven't connected it to the brake system or clutch yet so I can resite it but i have a question.

It is mounted on a bracket that tilts it back about 30 degrees rather than being horizontal. This looks like it is a design choice rather than an accident.

Does this mean I should mount it at the same angle when I re-site it?

If it has to stay at the same angle that severely restricts where I can put it.

Gary - where is the servo on the cars you have done? From memory, your later 5a's have a different set up anyway so probably not too relevent but any advice welcome.

[WorldClassAccident]

Update from the weekend with pictures of my mistake, I mean customisation.

https://sites.google.com/site/g46wca/2012-08-27

[Mister Towed]

I've fitted an aftermarket brake servo to my Spyder: it came with instructions that said it MUST be fitted using the angled mounting bracket for it to function properly. It also recommended a non-return valve in the vacuum take off and a hand formed 'U' bend to trap petrol in the vacuum hose.



Hope that helps.

[WorldClassAccident]

Frame on and body offered up.







Looks like the bonnet fits better now I have the rear of the body to align it to properly which is good news.

Just a bit of filler and sanding and it is ready to go!!

[davecymru]

All this talk of work progressing on G46 kits is starting to make me feel a bit light headed, i may need to go for a sit down.

Next things you know people will be claiming that they're driving them on the roads. Madness you hear me, sheer madness!

[WorldClassAccident]

If you look to the right of the last picture you can see what has been slowing my progress. Hic!

[davecymru]

Don't tease, I had to bin 5 gallons of homebrew cider the other week as my pressure barrel has a slight leak and killed me fizz

[WorldClassAccident]

Body loosely fitted and now I need to think about hinges. Damn you sneaky Sammios without doors!

[Nike55]

Originally Posted by WorldClassAccident

Body loosely fitted and now I need to think about hinges. Damn you sneaky Sammios without doors!

...and the choices are legion.

Were you thinking of knobbly, external hinges like a C-type or going smooth like a DBR2?

[WorldClassAccident]

My 'current' thinking is a side hinged boot lid.

Doors are more problematic. I would like hidden hinges rather than external ones but they are much harder to fit properly apparently.

I also need to source the hinges and the door catch. I was thinking of just a sprung bolt with a wire passing through the door pocket to pull it open.

[Nike55]

Originally Posted by WorldClassAccident

My 'current' thinking is a side hinged boot lid.

Doors are more problematic. I would like hidden hinges rather than external ones but they are much harder to fit properly apparently.

I also need to source the hinges and the door catch. I was thinking of just a sprung bolt with a wire passing through the door pocket to pull it open.

There is no reason not to keep it simple.

I can't really comment as I've not made my mind up yet on hatches, hinges, or locks, nor tried anything out.

I've never tried to fit a new body with hinges - others have done it 'straight off the bat' with little or no experience, so how hard can it be...? (famous last words). I guess if one fouls up its a 'simple' case of glassing over the disaster area and trying again?

I haven't started looking for guides on car door internal hinge fitting but will have a look later. I'm sure they are out there, if not on this site..

I think Lancelot favours this type of simple door lock for his creations:-

http://www.woolies-trim.co.uk/images...edium/1150.jpg

...which are very similar to Series Land Rovers.

You are in the unenviable position of being a bit of trailblazer on the 'G46' and I continue to look forward to your choices and experimentation with interest!