Monday morning
 

Right!

back to the problem, because the tolerances involved in the door glass missing the windscreen edge are so fine.

And we are talking one or two mm making the difference between opening correctly or jamming and causing damage.

Messing about like I am at present with bits of cardboard and ally clamped to the door, is not enough to provide a definite answer.

So the only way to be sure if what I am planning to do will work, will be to have the door set up properly with the window cut to size and bolted to it (as it will be on the finished car)

Then and only then, can I be sure it will either open correctly or not, and I can act accordingly.

To that end, I have ordered the lexan sheet with express delivery, so I can go ahead.

I will post when I can.

And many thanks to all who have given advice etc.

It might be worth knocking up the windows in (relatively cheap) Perspex so if you make a mistake the (relatively expensive) Lexan will not be wasted.
Guessing there may have to be a bit of trial and error...

Well I have ordered the lexan, but could always source some cheap muck to play with!
May just do that Landmannnnnn.

(But secretly, I'm pretty sure what I have in mind will work)

But there again, I thought for a year or so what I had in mind would work and it just didn't!!!!

Rather than waste polycarb won't plywood do for a mock up? Or card board?

I understand what you are saying, but each window will only cost about twenty quid anyway, and it wont be wasted either.

I will cut the window to its final shape, bolt it to the door and
make it open correctly. That will be done by manipulating the shape of the quarter light, which will only have a very small piece of lexan in it.
So hopefully, nothing will be wasted, and the worst case scenario is £20 lost , but I could always use the "wasted" bit to make the quarter lights, so I don't really see much of a problem.

Tuesday morning
 

Okay!

Today I started making the quarter lights.
I finished the drivers side, and the lexan arrived half-way through!

I am pleased with the result, and do think it looks better than it would have, if my original idea had worked.

I always get a lot of satisfaction out of starting with a flat sheet, and ending up with a three dimensional lump of something at the end of it.

I bolted the stainless screen top back on and it fits in better than I thought with the quarter light I have done.

I need to make a passengers one now and carry on with the fitting.

some pics:

[IMG]http://i928.photobucket.com/albums/a...psfc2b05b8.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...ps8e400caa.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...ps9a44a05a.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...ps43c35176.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...psa9d9de1f.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...psf82406eb.jpg[/IMG]

Neat, neat, neat.

Tuesday pm
 

Well, really a repeat of this morning, I now have the passengers quarter light finished/done, and placed on the car.

If I am brutally honest with myself, it is not as perfect as the drivers one, but to a good enough standard that I won't make another bugger!

That is all the brainwork, cutting, sawing, filing, grinding and polishing done and dusted, and another day I will cut and fit the lexan into the quarter light frames and make the side windows.

The good news is that it IS going to work, and the doors WILL (do) open without fouling, so the problem is done for, deceased, do-doed, morted, dead, lifeless, soulless, finitoed, endexed and very similar to Monty Pythons parrot, so is finally over.

And it cost bugger all and didn't take long either, praise be to the lowered!

Last piccies of the day:

[IMG]http://i928.photobucket.com/albums/a...ps64a22640.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...psaadc7d84.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...psfeb5d4d9.jpg[/IMG]

Wednesday
 

I was looking through Oxfords thread, and he said: "I got my ideas and techniques from Seanick"

That encapsulates perfectly the essence of this forum.

Basically to "nick" other peoples ideas!

Seriously, when I decided to make my own seats, I looked through the forum to see if anyone else had done their own, and I found some seats in red that a very clever fellah had made himself.

Although I wanted a different style, his seats looked so perfect and simple that it inspired me to make a start on my own.

Of course when I had finished my seats, they looked nothing like his, but it was looking at his seats which provided the driving force behind my efforts.

(I spent ages looking for where I got these pictures, but to no avail)

Pay attention Viatron!

So a big thank you to the unknown seat-maker out there!
Would be nice to see them in your finished car!

[IMG]http://i928.photobucket.com/albums/a...psf69e8a28.jpg[/IMG]

This was my first completed seat

[IMG]http://i928.photobucket.com/albums/a...ps71c92a5b.jpg[/IMG]

I'm very sad........I recognise those seats as being from Rattler's Miglia build -

http://www.madabout-kitcars.com/foru...?t=4428&page=2

I like them as well.

Why sad Oxford?

Have I missed something awful?

No - I just thought it was rather sad that I could identify a build thread from one photo!

Perhaps I should create a build thread quiz.

Not really! If I saw one pale green Triumph component, I would know instantly who owned it, and that wouldn't make me sad!!

You should be proud!

Scottie - By the looks of it, your quarter light solution will really look the part. :cool:

Good luck, Paul. :)

PS
Like Oxford I also remembered which thread those seats were on.

I love reading lots of build threads and am always amazed how clever some people are.

hi scotty some pic of my car on miglia thred /daves green miglia /some times we are to clever for are own good. rattler I read all your posts and love your car

Thanks rattler!

Well now you know that you were the inspiration which drove me to make my own seats!

But that's what this forum is all about.

I saw your car on your thread and do like it very much!
I can't wait for mine to be done.

Thursday
 

Today I had work that was unrelated to the build, but afterwards I set to and cut the drivers window and both quarter lights out of my lexan sheet.

I did a lot of measuring first, and had enough lexan to make three windows, and both quarter lights so I had room for error, or, if I was good, a spare window!

I also did a lot of research on the best ways to cut lexan, and decided to go the jigsaw tungsten-carbide route.

tungsten- carbide blades are a fairly new thing to me, I wanted some jigsaw metal cutting blades recent;ly, and ordered some tungsten carbide ones, kind of by mistake.

Well they arrived and have no teeth, just a flat blade with the "cutting edge"

tipped with tungsten-carbide. I used them on metal, and they were not much good, but on lexan, WOW terrific, I would never use anything else now.

I was dreading cutting the lexan, but with these blades, it was a doddle.

It does not so much "cut" as "grind" its way through, a bit like a 1mm cutting

disc, but with a reciprocation motion.

Makes the cutting work really easy, and a job to look forward to instead of dreading!

Like most other builders on this forum, my body shell has its anomalies,
because I made my windscreen surround, the left window is half an inch lower at the top than the drivers one.

And when I measured the passengers door, using the drivers side cardboard pattern, it turned out that the left door is one inch shorter for and aft, than the drivers one!

It really is as well that we don't see both sides of the car at once!

I don't even think a concours judge would spot that one.

[IMG]http://i928.photobucket.com/albums/a...psfd0ff172.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...pscd6056ec.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...ps388f27fd.jpg[/IMG]

[IMG]http://i928.photobucket.com/albums/a...ps5de670bf.jpg[/IMG]

You're doing a good job but that's a disappointing number of clamps :evil:

When you've finished the car you might like this http://www.christopherward.co.uk/men...07%2F08%2F2014

Wow, NO, I can't allow you to buy me that when I've finished!
It cost far too much!