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  #11  
Old 09-06-2011, 06:49 AM
invision invision is offline
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With the car's buck back in the shop we're starting to fabricate body panels. In regards to the hood, hatch, and door openings independent wire frame sections were created and bolted into the holes. Decided to start with the more straight forward structural sheet metal components that will support the exterior sheet metal skin.



Templates are created from drawings, dimensions and the wire frame. Since everything is identical from side to side - only revered... ie. rockers, inner wheel wells, A-Pillars, etc only one template is created and then transposed onto the sheet metal. Depending on the what structural components are being created we're running with 18GA & 22 GA



This is the rocker cover after being transposed from the template with the interior lip created after being run though the tipping wheel...with a soft lower wheel.



The blue line indicates the second exterior bend of the door seal step. The first exterior bend is 11/16" to the left of the blue line...one down and one up.. as per the shape needed.



Then using a shrinker/stretcher, the lips are stretched and shrunk to create the appropriate curvatures. Doing this a series of times and putting the different pieces together gives you this...



Here's a shot of the driver and passenger side door openings. With the wire door frame sections removed, the almost complete jam perimeter panels have been temporarily 'pinned' into place on the buck.

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Nick M.

A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes

Last edited by invision; 09-06-2011 at 02:08 PM.
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  #12  
Old 09-13-2011, 06:42 AM
invision invision is offline
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The beginnings of the rear cab wall. Pieces are laid out on the sheet metal in such a way as to reduce waste, yet created as large as possible to eliminate fitting and welding multiple pieces together.



Rear wall with final forming complete. The beads put in with the bead roller before the ends were rolled over.



Rear wall temporarily pinned into place with some self drilling self tapping metal screws to the jams and floor pans which were created earlier. This method allows the piece to be removed if necessary for tweaking. An old seat thrown in to add some perspective inside the cab.



Creating the drivers side scoop for ducting air into the rads. Once the desired shape is attained with cardboard, it's translated onto sheet metal.



Completed drivers side scoop shaped, welded and installed. The flange will be incorporated and fixed to the engine compartment's interior panels later.

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Nick M.

A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes
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  #13  
Old 09-20-2011, 06:16 AM
invision invision is offline
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Starting fabrication on the rear hatch's inner structure.



Taillight housing pieces...from paper to metal.



Taillight housing formed and welded up. Temporarily tacked into place.
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A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes
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  #14  
Old 10-03-2011, 08:47 AM
invision invision is offline
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Once the front trough pieces were created they were tacked together.


Carefully controlling the metal in the heat affected zone(HAZ) while welding the front trough to eliminate warpage.







Tipping one of the flanges on the wiper mechanism cover.



Using the foot actuated shrinker/stretcher I built used Triumph TR7 clutch & brake pedals to actuate the heads, the curve created after tipping up the flange is straightened on the cover.



With the pieces installed...it's slowly shaping up.



Rear hatch perimeter complete.

As a little side note, after completing the front moisture trough...I wasn't happy with the way it looked. So it was redone.

Thanks for looking.
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Nick M.

A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes

Last edited by invision; 08-31-2013 at 07:44 AM.
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  #15  
Old 10-03-2011, 09:59 AM
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JPMOSS JPMOSS is offline
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Nice work. It is really looking good. Thanks for posting your work. Johnny
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  #16  
Old 10-14-2011, 06:18 AM
invision invision is offline
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Thanks Johnny

Work on the vehicle's substructure continues...



Once the rear cab wall was fabricated and located the rear cab mounts were created. Since these will be supporting a little more than 50% of the cab's weight, they have to be tied into the sub structure really well.



... fabricated and installed. Ran with same gauge as the cab mounts since this area will also be supporting the cab and door hinges.



Horizontal DOM impact/support beam mocked up.

After temporarily pinning these panels in place work on the doors began...



Inner door shells tacked together. Exterior skins will be created later and then hemmed over the perimeter flanges.



Inner door shell gapped and mocked up. They need to be tweaked a bit yet for the seals to fit correctly. Access and mount holes will be created once impact beams, latch and hinge mounts have been fabricated.
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Nick M.

A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes

Last edited by invision; 08-31-2013 at 07:44 AM.
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  #17  
Old 10-16-2011, 05:26 PM
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coming along nicely
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  #18  
Old 10-18-2011, 07:23 PM
invision invision is offline
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Thanks Richard R2's body panels are coming out much quicker than I expected...
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A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes
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  #19  
Old 10-24-2011, 04:41 PM
Barry911 Barry911 is offline
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Fantastic work, and fasinating to see how you're tackling the inner structure. Very much looking forward to seeing this develop!
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  #20  
Old 11-01-2011, 09:25 AM
invision invision is offline
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Quote:
Originally Posted by Barry911 View Post
Fantastic work, and fasinating to see how you're tackling the inner structure. Very much looking forward to seeing this develop!
Designing the inner structure was a challenge. It needs to tie all the panels together and contribute to the frame's rigidity by acting as a stressed member, yet remain light and uncluttered. Thanks for looking Barry
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A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.

Some projects: http://www.facebook.com/iNVisionPrototypes
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