Hood frame preparation
 

Time for a small update.......

Since the New Year, I've been focussing my efforts on fitting a badge bar with driving lights and preparing the hood frame before the new hood is fitted in the spring. More on the badge bar when I have some decent photos so this update is about the hood frame.
The wooden battens that form the hood windscreen rail were very rotten from being left out in all weathers for many years so had to be remade.
Following the instructions in the Royale build manual I started by cutting two battens according to the dimensions given. These are then screwed together either side of a steel spine.

https://live.staticflickr.com/65535/...dc47aa05f0.jpgHood header rail by Sabrebuilder, on Flickr

You then have to make two cut outs in the lower baton for the Triumph hood catches.

https://live.staticflickr.com/65535/...46aa9f8a35.jpgHood header rail by Sabrebuilder, on Flickr

Trial fitting the hood catch

https://live.staticflickr.com/65535/...b8f944d4cf.jpgHood header rail by Sabrebuilder, on Flickr

Having screwed the two batons together you then have to plane a 15 degree slope to the top piece of wood and then chamfer the lower baton at 55 degrees. (Marked with a pencil line.)

https://live.staticflickr.com/65535/...8c8db5a23b.jpgHood header rail by Sabrebuilder, on Flickr

Lower baton now chamfered.

https://live.staticflickr.com/65535/...8a2e96bbb8.jpgHood header rail by Sabrebuilder, on Flickr

The front corners and top ends are then rounded.

https://live.staticflickr.com/65535/...b923a79567.jpgHood header rail by Sabrebuilder, on Flickr

The next picture shows how the hood side rails are located on the cant rail. My timber battens are thinner than specified so I added a 2mm thick aluminium strip between the battens and the steel spine. (photo taken before final paint preparation.)

https://live.staticflickr.com/65535/...9e8b9cf159.jpgDetail of hood side support by Sabrebuilder, on Flickr

I then dismantled the frame for painting. Whilst preparing the hood hoops for a fresh coat of paint I discovered they were very rusty beneath the black Hammerite that I put on about 11 years ago. They had clearly suffered more under the leaking hood than I first thought and I suspect they were not particularly well painted when first built.
I decided they needed to be stripped back to bare metal. This is one of the hoops after stripping, sanding and having been treated with Rustin's rust converter.

https://live.staticflickr.com/65535/...76a563a3ca.jpgHood hoops stripped for re-painting by Sabrebuilder, on Flickr

I then applied the first coat of primer.
I'm trying out "Direct to metal" Epoxy primer. Apparently, this creates a barrier that prevents moisture from reaching the metal surface, thereby reducing the risk of rust formation. They also claim it forms a strong bond with the metal surface, which helps prevent the paint or coating from peeling or flaking off over time.
It went on very nicely and dried to a pleasing smooth finish.

https://live.staticflickr.com/65535/...8ba5fa9f07.jpgHood hoops primed by Sabrebuilder, on Flickr

Following the application of primer I will be finishing the hoops in Midnight Blue to match the bodywork.

...............peter

Looking great!
Who would have known that the header rail is so complicated.

Cheers, Robin

:nod: yes, John Barlow was quite specific how he expected his cars to be built!

Potpourri
 

A little 'potpourri' of updates from my garage..........

I've finished off the hood header rail and given it a few coats of paint.

https://live.staticflickr.com/65535/...0e173b7abf.jpgHood frame assembly by Sabrebuilder, on Flickr

https://live.staticflickr.com/65535/...f1ac0ce349.jpgHood frame assembly by Sabrebuilder, on Flickr

I've also fitted the 'side arms' and the window seals.

https://live.staticflickr.com/65535/...d29c31d8d2.jpgHood frame assembly by Sabrebuilder, on Flickr

Bit of an optical illusion as the side arm is actually parallel with the top of the window.

I've also finished fitting the new reversing and fog lamps. Here is a picture of the fog lamp which is not very exciting!

https://live.staticflickr.com/65535/...d52b4fbeae.jpgFog Lamp by Sabrebuilder, on Flickr

And I've changed the side lights to LED as the originals were very dim. Not very obvious but here is a before and after shot. Nearside changed to LED and offside is the original bulb.

https://live.staticflickr.com/65535/...2b12a03d4e.jpgLED sidelights by Sabrebuilder, on Flickr

Well, that's all for now.
Hopefully, I'm off to the trimmers next week to have the new hood made and fitted.

.............peter

Hi Peter, as always, carrying out everything in the best way possible. Just a question, have you considered having your original hood frame modified so that you don't have to leave your seat to open the top. Instead you unlock the two screen locks, lift and drop it back behind the seats, and to close it, just the revers of that? Just an idea.
Keep up the fantastic work.

Looking forward to seeing the hood!
The last piece of the puzzle?
That rear fog light looks very nice. I don't suppose you remember where it was from?
Cheers, Robin

Hi Amir, no I hadn't considered modifying the frame, opting to keep to John Barlow's design to keep it simple.
I did see something about this in your recent article in the owners magazine but the picture wasn't clear enough to see what you had done.
Maybe something to consider for my future projects :icon_smile:
cheers, Peter

The hood is the last big piece but I still have a few other things to do before I would say it's finished :eyebrows:

The reversing and fog lights come from ebay like these....

https://www.ebay.co.uk/itm/232996587...Bk9SR86N94rAYw

Lots of sellers selling the same lamps so check the prices if you fancy buying some.
Of course, they are not 'E' or 'F' marked but they do have 'old school' glass lenses ad look nice!
Made of 'Chinese' stainless steel so not sure how long they will last?

cheers, Peter

I picked up my car from the trimmers this morning. I have to say that I am absolutely delighted with the result. Dave Joy at Hukes Car trimmers has done a fabulous job, a real craftsman! :first:

https://live.staticflickr.com/65535/...364d7d73_c.jpgNew hood by Sabrebuilder, on Flickr

https://live.staticflickr.com/65535/...69e7f872_c.jpgNew hood by Sabrebuilder, on Flickr

Details of front rail and hidem banding. Extra 'flap' above the windscreen to stop any water ingress.

https://live.staticflickr.com/65535/...bb1a2561_c.jpgNew hood by Sabrebuilder, on Flickr

Latching handles. Dave made up a new piece of internal trim to cover the rail. Looks fantastic and a major improvement.

https://live.staticflickr.com/65535/...db27fed6_c.jpgNew hood by Sabrebuilder, on Flickr

https://live.staticflickr.com/65535/...dcd252e3_c.jpgNew hood by Sabrebuilder, on Flickr

https://live.staticflickr.com/65535/...0fc781b3_c.jpgNew hood by Sabrebuilder, on Flickr

Next job, when time permits, is to fit some nice real leather seats :eusa_dance::eusa_dance:

....peter

Looks very nice :)

New seats
 

The somewhat scruffy MX5 seats were always a temporary measure to get me through the IVA. My original plan was to have these seats recovered so I was on the look out for another pair. The plan was to get another pair to use while mine were being professionally recovered. Recovering costs in leather by my trimmer, who did my hood, was estimated to be about

FORUM PLAYING UP AGAIN!! I'LL TRY AGAIN TOMMOROW>>>>>

New Seats
 

Okay, so let's try that again...........................

.................................................. .................................................. .........................................

The somewhat scruffy MX5 seats were always a temporary measure to get me through the IVA. My original plan was to have these seats recovered so I was on the look out for another pair. The plan was to get another pair to use while mine were being professionally recovered. Recovering costs in leather by my trimmer who did my hood, was estimated to be about GBP2k in leather and about GBP1k in vinyl.
Whilst looking for another set, a pair of cream leather MX5 seats came up on ebay for GBP300. They looked to be in good condition in the pictures so I snapped them up. When they arrived I found they were in nearly perfect condition, just a bit dirty.
This picture is one of the leather MX5 seats. In remarkably good condition but slightly the wrong shade of cream/beige. I tried one in the car but it didn't match the cream vinyl and looked awful.

https://live.staticflickr.com/65535/...266d718c_c.jpgNew leather seats by Sabrebuilder, on Flickr

Due to the 'new' leather seats being the wrong shade of cream I decided to have a go at re-colouring them. There are companies that do this professionally but I thought I would have a go myself.
I found a company called Carbusonic that offered to provide a leather coating colour matched to my vinyl dashboard surround. You first have to thoroughly degrease the leather with their specialised prep fluid and then sand with 600 grade abrasive paper. Then three coats of the leather coating. You can use a hair drier the dry the coats to speed up the process. This picture shows the head rest half done. Top part is coated and lower part is the original leather.

https://live.staticflickr.com/65535/...e798a3bf_c.jpgNew leather seats by Sabrebuilder, on Flickr

This is the passenger seat after two coats.

https://live.staticflickr.com/65535/...9f1c1938_c.jpgNew leather seats by Sabrebuilder, on Flickr

Close up after three coats.

https://live.staticflickr.com/65535/...e8cd832f_c.jpgNew leather seats by Sabrebuilder, on Flickr

The leather coating covers the small cracks in the leather but follows the natural gran and makes them look like new. It surpassed my expectations.

https://live.staticflickr.com/65535/...aea605c5_c.jpgNew leather seats by Sabrebuilder, on Flickr

The company that makes the leather coating recommends you use sponge brushes. I was sceptical as I had never used these before but they worked really well. Easy to use and left no streaks or brush marks. Each seat took about 1 day including preparation. The prep solution cost GBP22 and the colour matched coating cost GBP34. So with the brushes and sandpaper about GBP65 for two seats.

https://live.staticflickr.com/65535/...6ffd185f_c.jpgNew leather seats by Sabrebuilder, on Flickr

And here is the first seat fitted.

https://live.staticflickr.com/65535/...95be1a6e_c.jpgNew leather seats by Sabrebuilder, on Flickr

Came out much better than expected so I'm delighted! :eusa_dance:

Good job, they look nice, I've been considering MX5 seats for the Sportster as the ones I have are not the best seats, even if they look the part.