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  #21  
Old 04-28-2010, 12:26 AM
John_Alba John_Alba is offline
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James-- yes I will use .063 3003-- I am still at a loss for the inner structure I really like what Kirkham is doing but I lack the tools and experience to run the tube.

Kerry suggest .125 aluminum angle which I think is a more realistic option- what is your take? I am having a series of mini meets to build the structure along with shutting the shop down for a couple of weeks- my helper and I will be doing a lot of the work.

It would be great if you can make it out to the meet- I hope you make it

John
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  #22  
Old 04-28-2010, 09:10 AM
James Bowler James Bowler is offline
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I will try but CA is a long way from me . Yes the inner structure is the hardest . try making bulheads out of steel sheet metal that will fit inside the fiberglass body and then fit the new body to it . you might have to compensate for the glass thickness . the less bulkheads the better like one in front of the driver and one between the drive and motor
James
After looking at your pics . Try this where the funny oval looking tubes are tack 19 ga steel to it spreading outward . make an outside pattern from your fiberglass body right at the point where those tubes are then transfere the pattern to the sheet tacked to the tubes . then cut it 3/4" wider and flange it 90 deg . now when you copy the body it will fit to the chassis . As for the doors copy the panels in the door jamb and make it 3/4 " longer and flange them 90 deg . now for the body you can either rivit it to the steel or bend it over the flange
What type of rear suspension does that kit run and what kit company is it .
James

Last edited by James Bowler; 04-28-2010 at 09:28 AM.
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  #23  
Old 04-28-2010, 10:07 AM
John_Alba John_Alba is offline
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Default turning the flange "flange jig"

Well, James I think I've have an idea to help with the inner structure.

Basically, an exoskeleton in .125 steel angle iron. The perimeter only is formed with the angle iron and welded together. The vertical edge of the angle iron terminates at the edge of the panel.

Once the exoskeleton (flange jig) is made .125 aluminum flat stock (.500 to 1" wide) is placed on the inside of the flange jig and located with a bolt every 6 to 10 inches.

The panel/part is formed with a buck, paper pattern or flex pattern- arrange the part inside the flange jig ( mark and drill the locating hole in the part) and bolt the inner aluminum strip, sandwiching the part between the angle iron. (using the bolts and clamps the flange can be registered and turned in the jig)

IF the part has a feature at the flange location that can not be turned between the angle iron and the aluminum strip then- the angle iron is formed around the feature and duraglass is used both on the angle iron and the aluminum strip to replicate the feature on the body. (essentially creating a male and female of the feature)

This is what I've come up with to supply the 3D information of the flange area with out the creation of a female/ male buck. With this jig all the edges can be turned with the correct relation to one another and in the correct arrangement.

John_Alba

ps- I forgot to mention all the inner structure is formed to match the inside of the flange jig- with the aluminum strip removed and a .063 shim in it's place the inner structure can be made to live in it's correct location without any guess work.
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  #24  
Old 04-28-2010, 10:08 AM
John_Alba John_Alba is offline
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I will post photos this weekend of the jig and method. ---

John_Alba
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  #25  
Old 04-28-2010, 12:07 PM
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red baron red baron is offline
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What days and times this weekend? Anyone want to carpool from the San Diego/Oceanside area?
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  #26  
Old 04-28-2010, 09:38 PM
John_Alba John_Alba is offline
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we are going to start this saturday between 8-9am. right now I've got three confirmed-

- let me know if you are coming up and I'll give you directions


John 714 3281028
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  #27  
Old 04-28-2010, 10:50 PM
John_Alba John_Alba is offline
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James- I was looking online and is Livingston Library and this is what I found

http://www.amazon.com/Indy-Cars-1960.../dp/1583880526

can you tell me which book is the one you would recommend?

John
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  #28  
Old 04-29-2010, 08:30 AM
James Bowler James Bowler is offline
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Sounds like you have it under control i can't wait to see the progress

This is the book i have

http://www.amazon.com/Porsche-Spyder...7&sr=1-1-spell
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  #29  
Old 04-29-2010, 10:51 PM
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Kerry Pinkerton Kerry Pinkerton is offline
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John, I don't know if you saw this on MM before they lost the data but you should look through this recreated thread:

http://allmetalshaping.com/showthread.php?t=1254
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  #30  
Old 04-30-2010, 09:34 PM
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red baron red baron is offline
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Quote:
Originally Posted by John_Alba View Post
we are going to start this saturday between 8-9am. right now I've got three confirmed-

- let me know if you are coming up and I'll give you directions


John 714 3281028
Will be leavin down here about 7:30, will call on the way for directions.
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