Well the rear is now pretty much complete. Just need to add the lights and then that's it. As you can probably see there were hundreds of rivets to set and, just to make it even more interesting, the rear top panel is also bonded with epoxy resin. The result is very strong!

That just leaves (bodywork wise) the dash top and bonnet to do. Light at the end of the tunnel at last.

Cheers, Robin

https://c1.staticflickr.com/1/390/18...400444e7_c.jpgDSCF2009 by Robin Martin, on Flickr

https://c1.staticflickr.com/1/324/18...fddc256a_c.jpgDSCF2006 by Robin Martin, on Flickr

https://c1.staticflickr.com/1/514/18...28d6f309_c.jpgDSCF2004 by Robin Martin, on Flickr

And some experiments in proper metal forming (needed for the dash top)

https://c1.staticflickr.com/9/8884/1...0bb2ccaf_c.jpgDSCF2010 by Robin Martin, on Flickr

Lovely work, where did you get that edging? Are you painting the car or just polishing it?

I am hoping to polish it if I have the patience ;-).

The edging is the same as used on the Morgon 3 wheeler. Fellow Pembleton builders used to have a source but unfortunately it seems to have dried up....

Cheers, Robin

Looking very smart!
Is that very shiny thing the silencer??

Yes. 1 per cylinder. Good job it's not an m20 lol.

Robin

Some more progress despite the fact I have been also spending some time fault finding on the Sportster. I have made a prototype of the drivers side dash top, cowl - call it what you want. It's not bad for a first attempt although I will make it again now I have had some practice.
The flange that fits allong the dash hoop has to be stretched in order to get the shape. After evaluating various methods and tools I have used the old fashoined way of belting it with a hammer. Ok - so it's a special stretching hammer - but much cheaper than buying a proper shrinker/stretcher as used by some bodyshops. The marks left by the hammer will be hidden by the bonnet tape.
I have shaped the cowl in such a way that it covers the steering wheel thus hopefully preventing hands getting too cold. bending it in such a way means it is suprisingly strong. Even so I will be re-inforcing the edge with a U shapped ali trip strip.

Cheers, Robin

https://c1.staticflickr.com/1/279/18...9533d851_c.jpgDSCF2028 by Robin Martin, on Flickr

https://c1.staticflickr.com/1/456/19...5018056f_c.jpgDSCF2026 by Robin Martin, on Flickr

I have completed the scuttle top. In the end I gave in and bought a shrinker/stretcher to make the flange. And to answer my wife's question (lol) yes it is supposed to be asymetric! The offside has been modified to follow the outline of the steering wheel.

https://farm6.staticflickr.com/5678/...b0e12a1b_c.jpgDSCF2037 by Robin Martin, on Flickr

https://farm6.staticflickr.com/5679/...1afa4154_c.jpgDSCF2050 by Robin Martin, on Flickr

https://farm1.staticflickr.com/721/2...47e4855a_c.jpgDSCF2038 by Robin Martin, on Flickr

I have also added a quick release mechanism to the steering wheel as, with my chosen seats, getting in and out was proving a bit tricky!

https://farm1.staticflickr.com/622/2...050a8c9d_c.jpgDSCF2055 by Robin Martin, on Flickr

https://farm1.staticflickr.com/609/2...f0f2184e_c.jpgDSCF2041 by Robin Martin, on Flickr

https://farm1.staticflickr.com/722/2...c4be356b_c.jpgDSCF2043 by Robin Martin, on Flickr

Just the bonnets to do now and that just about completes the bodywork. Light at the end of the tunnel!

Cheers, Robin

Robin

Beautiful workmanship it will be a really stunner when finished.

Can I just ask , was this bracket made of aluminium ?

Not a kit car builder myself yet , however have done loads in the bicycle world and we gave up on aluminium for brackets as the weight saving is negligible and if something is going to break with load and vibration it will be the most awkwardly placed bracket.

regards Paul

Thanks for the encouraging words Paul :-). No the bracket is made from a bit of galvanised steel I had hanging arround the workshop. Hence the funny colour!

Cheers Robin

Bodywork complete excpet for the cycle wings. Not long now.... (90% complete and 40% left to do :-) )

https://farm1.staticflickr.com/688/2...d112b01a_c.jpgDSCF2068 by Robin Martin, on Flickr

https://farm1.staticflickr.com/664/2...30737488_c.jpgDSCF2062 by Robin Martin, on Flickr

https://farm1.staticflickr.com/753/2...3567eb25_c.jpgDSCF2073 by Robin Martin, on Flickr

https://farm6.staticflickr.com/5708/...434e51d8_c.jpgDSCF2072 by Robin Martin, on Flickr

Cheers, Robin

Robin

This is looking superb.............it will be really nice to see it on the road.

How far from IVA are you realistically?

Mike

Some nice panel work here Robin, a friend of mine at work has just made himself an English Wheel for forming petrol tanks and panels for the motorbikes he builds, we made him the top roller and he purchased a set of bottom rollers from the net and incorporated an old lathe tail stock to adjust the bottom roller, it works a treat, maybe one would have helped you out on your panel shaping, they don't leave hammer marks in the material.

Great work Robin. Really like contrast between the aluminium body and the brass nose. :)

Thanks Mike.

Middle of next year I hope if I don't pontificate (fart arround) too much...
It actually requires an MSVA (Motorcycle Single Vehicle Approval) test as it qualifies as a heavy trike. Much less onerous, although it still has the infamous radius test, and far cheaper :-)

Cheers, Robin

Fitted the wheels this weekend. Not quite so simple as it sounds as the wheels and hubs are combined. The wheels are made by Pembleton by machining down the 2cv hubs. Makes for a very low unsprung weight which should contribute towards the handling. Riding a bit high at the moment....

https://farm6.staticflickr.com/5825/...41338ab9_c.jpgDSCF2074 by Robin Martin, on Flickr

Robin

Looks awesome :)

Stunning.

Wow, that looks stunning!!

Mudguards
 

I am trying to do something clever to support the mudguards as they rotate. They are very light being made of aluminium - much lighter than the Marlin. Even so I want to design out the bouncing up and down I get on the Marlin.

So I have been doing some experimentation trying to find the rotation centre by extending the line of the king pin up to the top of the tyre..

https://farm1.staticflickr.com/571/2...e05711a5_c.jpgDSCF2078 by Robin Martin, on Flickr

https://farm6.staticflickr.com/5720/...5b900fec_c.jpgDscf2079 by Robin Martin, on Flickr

Looks a bit Heath Robinson but I think it's done the trick.

I also made some MSVA friendly covers for the ends of the suspension arms.

https://farm6.staticflickr.com/5726/...86795225_c.jpgDSCF2081 by Robin Martin, on Flickr

They clear the bodywork by at least 2mm....

Robin

Nice