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Go Back   Madabout Kitcars Forum > Mad Build Area > Sammio Builds and discussions

Sammio Builds and discussions Sammio bodied car builds and specials

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  #341  
Old 20th June 2019, 07:31
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Dpaz - Unfortunately, a gazebo won't work on my driveway due to the slope and the 'permeable' paving which prevents anchoring.

I will not know if the 'ramming' work has fixed the fuel problem until I get a chance to tighten everything up and try again.

Cheers, Paul.
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  #342  
Old 21st June 2019, 17:00
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Quick Update…
Due to the numerous failed attempts to start the car, I figured it was worth topping up the battery.



This morning I had my second attempt at getting to the bottom of my fuelling problem.

Eventually I found a kink in the fuel line near the rear of the car.
( Not easy to see in the photo. )



But the P-Clip bolt was next to impossible to reach, so I had to remove the wheel.



I then bit the bullet and cut the pipe off before the kink.



Note: I will be making a cleaner cut a little further back.

This allowed me to remove the hard pipe from this point back.
( Which runs through the boot floor and up to a rubber hose connecting it to the petrol tank. )



There was definitely something restricting/blocking this section of the pipe.

The good news is I was able to feed clothes line through from the front...



All the way through to the back of the remaining section of hard line.



I then had to quickly cover everything back up.



So I could try a local Motor Factors for some replacement copper and rubber fuel lines.
( I am going to replace all of the fuel lines while I'm at it. )



Unfortunately, they didn't have anything in stock, so I've had to order some from Ebay.
( But they will not arrive until mid week. )

At this point I figured I should test/confirm the problem was this rear section of pipe.

So I reattached some pipes at the front to a jerry can.



I know a photo isn't the best way to show this, but the engine fired up with no issues.



I even left it running for a while just be be on the safe side.

To say I am a very happy bunny would be a huge understatement.

Until next time, take care, Paul.

PS
I have a ton of replies to post on other threads and I'll try to do that over the weekend.
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  #343  
Old 22nd June 2019, 05:36
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Quote:
Originally Posted by Paul L View Post
Dpaz - Unfortunately, a gazebo won't work on my driveway due to the slope and the 'permeable' paving which prevents anchoring.

I will not know if the 'ramming' work has fixed the fuel problem until I get a chance to tighten everything up and try again.

Cheers, Paul.
Bouncy Castles hired for children's parties use relatively small sandbags to anchor them. A bag of sharp sand and 4 rubble sacks? This could provide the means to use a cheap gazebo or garden greenhouse as a temporary shelter. (I have been looking into cheap spray booth solutions for my Lambretta and am considering the latter).
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  #344  
Old 23rd June 2019, 08:35
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Barber – Thanks for the suggestion.

I did look at all variations of weights, but the problem of the slope remains.

If anything, the slope of my driveway caused more problems than working outside!

Anyway, I spend a lot of time working in the garden yesterday.

So, fingers crossed, I hope I will be able to spend some time on the car today.

Cheers, Paul.
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  #345  
Old 24th June 2019, 07:56
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Sunday - Part 1
I have to wait a few days for the new fuel pipes to arrive to get the car back on the road.

Therefore, I figured now was the time to jump right in and tackle lining the cockpit walls with alloy.

I removed the passenger seat and tried hard to forget about how many hours I'd spend fitting it.



Next, the seat belts came out.



This gave me a clear run to make the extension piece I needed for the passenger side panel.



Note how lumpy the back wall is!

With the extension piece added I had one side complete.



My original plan was to extend this panel further at the rear so it would wrap around the rear corner.

There is plenty of room on the aluminium sheet to do this.



But I realised the rear wall would be higher than the sides, like so.



This is due to this 'hump' section of original Spitfire.



Note:
The 'white' square on the rear wall was caused by me trying to shoved an oil can behind the passenger seat.

This is a long winded way of saying that I will need a pair of corner panels, something like this.



End of Part 1…
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  #346  
Old 24th June 2019, 07:58
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Sunday - Part 2
This is the full size of the smallest of the three alloy panels I bought.



Which could be trimmed down nicely to fit the middle of the rear cockpit wall.



Although it was a better fit when I remembered that it was supposed to include room for my access panel.



Next I removed the driver's seat and belts before making an extension piece for that side.



By the time I had made a corner section for this side I was left with something like this.





The next step will be to cut these shapes out and start fitting them.



But that is a job for another day, so until then, take care, Paul.
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  #347  
Old 25th June 2019, 05:21
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Monday
I've now cut out all five panels for the cockpit walls.



I used a hole saw for the seat belt mounting points to provide a nice cut out.



I am sure there will be some further trimming required when I test fit these.

Which will be followed by drilling the holes required to fix the panels to the cockpit walls.

After that I will then clean up / round / soften all the edges before actually fitting them.

Cheers, Paul.
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  #348  
Old 25th June 2019, 08:41
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Nice one, Paul. What is that finish called?
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  #349  
Old 25th June 2019, 09:12
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Those look really good, can't wait to see them fitted
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  #350  
Old 25th June 2019, 20:50
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Oxford - The finish is called 'stucco' and these were left over sections from a building site.
( Think the air conditioning ducting that Bruce Willis always seems to find himself in. )

My hope was that this surface would 'absorb' the lumps in the cockpit walls better than milled alloy.

Check the post below to see if you think this has worked in practise.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Piguin - Cheers and I was able to take a big step towards getting these panels installed today.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Tuesday
Confession time…

The back of the cockpit wall has a small unfinished section, see the grey strip in this photo.



This is because when the car was in primer, I was planning to paint this section BRG.

But when I started painting, I realised it should be part of the cockpit walls and be painted black.

Unfortunately, by this time, the seats were fitted and I didn't want to remove them to get some black paint on.
( As fitting them almost broke me at the time. )

So I need to touch up the black paint (Tetroseal) before the panels are fitted.

However in the meantime, I make a start on fitting and shaping the rear panel.



This involved testing/marking/trimming/hammering/etc.

Here is the work in progress along the top edge of this panel.



Which will tuck in under the painted edge of the cockpit.
( This photo is from the passenger side. )



Obviously, I can't get a tight fit until the panels are screwed into place, but this gives you the general idea.



Hopefully, the black Spitfire edge at the bottom of the rear cockpit wall matches the start of the Spitfire bulkhead at the front.



Note: I still need to make access panels for the side mirror bolts.

These two photo show the lumpy nature of the rear cockpit walls.





And this gives you an idea of the alloy trimming required.



The next step for these panels is to tidy up all the edges, but that is a job for another day.

So until next time, take care, Paul.
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  #351  
Old 25th June 2019, 21:40
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Looking good Paul, will you paint these panels?
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  #352  
Old 26th June 2019, 07:35
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Molleur - The plan is to leave the alloy panels as they are.

But I may add some of the 'sponsor' stickers I didn't add to the outside of the car.
( Assuming they stick to the stucco surface. )

Cheers, Paul.
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  #353  
Old 26th June 2019, 08:46
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Quote:
Originally Posted by Paul L View Post
Molleur - The plan is to leave the alloy panels as they are.

But I may add some of the 'sponsor' stickers I didn't add to the outside of the car.
( Assuming they stick to the stucco surface. )

Cheers, Paul.
That will look good, so with the stickers.
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  #354  
Old 26th June 2019, 20:48
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Molleur - Cheers.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Wednesday - Part 1
The two parcels that arrived in the the post lead to a slight change in plans…





But before I tried to fix my fuel line problem once and for all, I did a bit of painting.

I started by masking off the BRG edge of the rear cockpit wall.



Before slapping on some Tetroseal.



I also covered the fibreglass between the cockpit wall and the petrol tank.



I then removed the masking tape to let the Tetroseal dry.



Note:
Most of this will be covered by the alloy panel, but any gaps at the edges will now look black rather than grey.

Then I started replacing the rubber fuel lines in the engine bay.

This is the new hose from the fuel pump to the carb.



The new hose was longer than the one I replaced to allow a better routing.

I also split the old hose to cover the braided oil line to prevent any potential rubbing.

Two new sections of hose connected the fuel filter to the hard line.



So far, so good.

End of Part 1…
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  #355  
Old 26th June 2019, 20:48
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Wednesday - Part 2:
For the new copper fuel line I had to use my cheap and cheerful pipe bender.



I then cut the old fuel line a bit further back to mock up the position of the new.
( As I wanted the end of the new pipe to be held by the P-Clip. )



At this point the rest of the pipe was just sticking up in the air.



After some more pipe bending, it was time to cut it to length.



Then I could fix it all into place, with just a very short rubber hose join.



Followed by a nice curve up into the boot floor.



To another P-Clip inside the boot.



Before cutting the new rubber hose (also seen above) to the right length.



Note:
The rubber hose is zip tipped to the framework, but I couldn't get a decent photo.

Then it was the moment of truth as I tried to start the engine.

The good news is that is fired up and ran without any problems.

So this photo is just like the last one except there is no petrol can in the shot.



Obviously, I couldn't take the car out for a test ride as there are no seats in it.

I also remembered that I need to make the alloy access panels for the side mirrors before I fit the panels.

As I need to drill some holes in the cockpit side panels for the access panels' fixing screws.

So until next time, take care, Paul.
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  #356  
Old 27th June 2019, 14:08
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Made a start…
Normally, if I wanted to clean up metal edges I would get my angle grinder out.

However, as the alloy is so thin, I'm sure I would grind off too much too fast if I did.

So it was back to hand files and sand paper to soften up all the edges.

I also drilled the first round of hole to fix the panels to the cockpit walls.

I only had time to do the rear wall panels.





I also knocked up a quick test piece and decided to use just a screw, not a screw and washer.



So to fix the panels I will need these three bits for my drill.



One to drill the hole in the alloy, one to drill a pilot hole in the wall & one to fix the screw in place.

Whilst this panel looks good...



The top edge of the panel was sticking a little bit too far.



The layer of Tetroseal I added may have something to do with this, or more likely operator error.

Either way, I had to spend some time marking and trimming the top edge to get a better fit.

So now I have to go back and smooth out this top edge again.



All was not lost though, as I was able to mark up where the main panel over lapped the passenger side corner panel.

So after drilling a few more holes, I was able to fix this in place.





Unfortunately, I managed to break my pilot hole drill bit.



But I had run out of time by this point, so I packed up for today and will try again tomorrow.

Cheers, Paul.
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  #357  
Old 27th June 2019, 19:38
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Paul Glad to see you'v fixed the fuel supply problem and the paneling is coming along nicely. I'v found that a small surform plane works very nicely on the edges of thin alloy sheet.

Cheers
Derek
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  #358  
Old 29th June 2019, 05:49
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Deggsy - Cheers Derek.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

[Meatloaf] Two outta three ain't bad [/Meatloaf]

Started off by tidying up the edges of the two side panels.



Then overlaid my simple guide to where the framework sits behind the panels.



Before marking up and drilling a lot of holes, all of which had to be de-burred.



Then I started the process of fixing the main rear cockpit wall panel into place.

At the time, it seems to make sense to start at one end and work my way across.



Unfortunately, I should have started in the middle and worked my way out instead.

The reason I know this?

Well, as I hammered the panel flat and screwed it into position, the 'center' moved to the left.

Which meant a lot of the holes I'd made for the access panel were now in the wrong place.



Thankfully it was easy enough to enlarge some of the holes.



But for others, I ended up cutting out a 'path' from the main access panel hole.

So at this point, it looks a bit of a mess, but none of this will be seen when the access panel goes back on.



Note:
Thankfully, I remembered to leave the final few screws from the left hand edge at this point.

As I needed to test fit the driver's side corner panel.



This allowed me to mark up and drill some more holes in this panel.



By this point' I had learnt not to pre-drill the holes where the two panels would overlap.

Instead, I simply started at the top of the overlap and worked down one screw at a time.
- Carefully drilling out the alloy on the lower panel through the top panel hole.
- Then drilling the pilot hole in the plywood wall.
- Fix screw in place.
- Hammer panel flat and repeat.

By working my way down from the top edge, this was the final 'lumpy' join at the bottom.



End of Part 1…
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  #359  
Old 29th June 2019, 05:50
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Friday - Part 2:
Next I had a look at the side mirror mounting point on the passenger side.



Note:
You can see another 'edge' than I thought was going to be BRG, but should have been black and ended up a messy grey.

Made an initial cardboard template for the access panel and marked up the main panel for a slight trim in the corner and some fixing holes below the panel.



Cut the access panel out of milled aluminium and drilled all the holes required in both panels.



Despite giving the main passenger side panel an extra trim before I started, I still ended up with a problem corner.

Not a great photo angle, but this is leaning over and looking down on to the top edge of the rear corner of the passenger side.



Part of the problem is that at this point, the join of the cockpit wall and the body shell is almost flush.

So I needed to trim a bit more off, which was tricky as the rest of the panel was already screwed in place.

Thankfully, I was able to carefully tidy the edge up without accidentally running a metal file across the body shell's paintwork.

By this point, I'd spent many hours cooking in direct sunlight, bend over the body shell trying to fit everything as best as I could.

The fact that in some cases, each screw was taking three drill bit changes to fit was not certainly helping.

So when my wife suggested we ate out, I gratefully took that as a sign to pack up for the day.

Before I post the 'reveal' shots, remember this build is not a quest for perfection.

So whilst these panels may not be perfect, they are miles better than the Tetroseal finish I had before.







Notes:
- I didn't actually notice the fold line where I had to trim the corner edge, so I'll try to hammer that flat next time.
- I will be adding an extra horizontal row of screws along the middle of the panels to eliminate any possible vibration issues.

So 'two outta three' sides completed, but technically 'four outta five' panels fitted.

Until next time, take care, Paul.
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  #360  
Old 29th June 2019, 07:49
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Will you add a small rubber slip on edging to protect your self from the sharp edges???
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