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  #91  
Old 12-24-2017, 06:51 PM
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racer-john racer-john is offline
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Default BMW 320 Group 5

I wish you warm holiday greetings and a happy, healthy and safe 2018!
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  #92  
Old 12-29-2017, 03:56 AM
skintkarter skintkarter is offline
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And to you also John!
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  #93  
Old 01-10-2019, 02:52 AM
skintkarter skintkarter is offline
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Happy New Year everybody.

Well its been a while and some serious distractions along the way, but back to the E21 Group 5 project and the bodywork.

Amazingly and I'm not sure if it was inspired by our long-running stumblings, but another Group 5 E21 is being built locally, although with quite a dissimilar budget... This chap's build has a similar budget for the composite work alone as we have for the total build. Bloody epic! Anyway the upshot of this disclosure is that they have scanned a standard car and also scanned a newly restored and correct original Group 5 car with our iteration of the bodywork. Post this they have had carbon fibre panels moulded and were kind enough to lend me a RR Guard for a week to help me with the construction of the buck.

OK, I've succumbed to the wise words from my local metalshaping god buddy and decided that in fact an MDF buck is possible...

Once I had the radiator openings formed up in 10mm rod, I then was able to make sure that the resulting panels should clear the radiators. It was then possible to remove the rads and use the pods as a flat base to build the buck from.

I made up some aluminium angle sweeps from 1.2mm and stretched and shrank these to fit the carbon fibre guards to give me profile checks for the rear ducktail and main shape.

Again my local buddy to the rescue with the suggestion that the ducktail portion be made removable so that I could wheel the main bits to the buck and then smack up the ends for the spoiler returns.

He also put me onto the boatbuilding ruse of using a long piece of stiffish plastic to check the flow of the stations. I had some local guys cut me a 2.5mtr strip of 25x10 HDPE to use as a fairing check - works brilliantly.

I really don't like MDF dust...

Messed around with the stations on the RH side until I had the flow I wanted and it was pretty close to the sweeps I made from the CF parts.

Trouble is with most of the original cars that have seen some racing action is that the glass fibre panels are photocopies of photocopies of the originals and thus the fit and detail lines are all over the place.

Figured that the best way to form the tail was with a solid buck as a hammerform/flowform.

I really don't like MDF dust, neither does the cat, the neighbour's cat, my trees and just about everything in a 100mtr radius depending on which way the wind was blowing.

Chewed out the first one outside with a combination of chainsaw and the orange spinning wheels of death on a 4" grinder. Got a bit smarter I think with the second side and bought a super quality $98 Chinese marquee which I erected inside the shed. It reminded me of a scene from 'Lock Stock and Two Smoking Barrels' about the inquisition into the recent blagging of the local Bookies. Happily nobody died and I still have all of my digits.

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  #94  
Old 01-10-2019, 03:52 AM
touringgarage touringgarage is offline
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WOW
Perfect Work !
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  #95  
Old 01-10-2019, 04:13 AM
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That should help the building of them for sure. Nicely done.
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  #96  
Old 01-10-2019, 07:37 AM
cliffrod cliffrod is offline
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That's looking great, Richard.

I have a big stack of mdf here, supposedly to use for a buck or two, for a long time still haven't. did you stabilize it with anything more than the glue between the individual sheets?
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  #97  
Old 01-10-2019, 08:30 AM
Stretch Stretch is offline
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wow indeed! most excellent Richard. can't wait for further progress!
Matt
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  #98  
Old 01-10-2019, 11:32 AM
dwmh dwmh is offline
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Superb job Richard. You do a quality job. No corners cut.
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  #99  
Old 01-10-2019, 02:28 PM
skintkarter skintkarter is offline
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Quote:
Originally Posted by cliffrod View Post
That's looking great, Richard.

I have a big stack of mdf here, supposedly to use for a buck or two, for a long time still haven't. did you stabilize it with anything more than the glue between the individual sheets?
Thanks AC, no just normal PVA adhesive. The first lot I'd had in the workshop for probably 12 months and having never laminated much MDF before, I just put squiggles of glue on one surface, then placed and moved the second sheet around to try and distribute the glue. The bond wasn't perfect and some of the edges pulled up when I was carving. The second side I actually used a small paint roller to ensure 100% coverage - much better result. However in both cases there were issues with the exposed 'contour lines' of the sheet edges not wanting to sand as easily as the surrounding material - hence leaving a slight ridge. Must get me a 5 axis CNC...

Thanks Bernhard - not as complex as your Alfa mask!
Cheers Marcus - getting excited about wheeling some alloy soon
Very kind Matt - lots to learn yet and I'm planning on trying O/A
Thanks David - I'm 63 now so have seen a few times what generally happens when folks cut corners Still can't seem to get this through to my youngest!
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  #100  
Old 01-11-2019, 02:48 AM
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very cool stuff richard! top job as always, nice to see you back at it. not be long now before your kissing the tyre walls? lol, next year maybe?
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