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  #1  
Old 07-05-2014, 10:41 AM
Cardiffrob Cardiffrob is offline
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Default First go at body building.

I've repaired aircraft before, mostly engines and mechanicals before getting a job flying them, which then paid for my toys. I know one end of a hammer from another but every skill set I've used here has been gained through websites like this one!

Latest toy is a 1935 Austin 7 that arrived as 2 car loads of bits that hadn't been bolted together for at least 40 years.

Anyway, the mechanicals were easy but the cost of buying or restoring a decent body was more that the car would be worth so I thought I'd watch a couple of Youtube videos and then have a go.

Progress is as you can see below...


Original welding repairs needed a bit of TLC.



Rolling chassis. Changing the wheels and the springs later brought it down to a sensible height.


I started by beating out some 3D shapes as per the videos using plywood formers and a BFH. It took ages to get the metal annealed with a small disposable blowtorch.


More hammering, some bolting (Line those screw slots up!) and some tips on forming 'dimples' from this website.


Progress so far.

It took a very long time to work out the shapes and angles to form the top of the dashboard panel. Not something I'd like to do ever again, along with trying to wire the edge. Is there a requirement to use the same material for the wired edge or can it even be left out and just a U-channel formed? I haven't found any wire of a sensible size.
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Last edited by Cardiffrob; 07-05-2014 at 10:44 AM.
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  #2  
Old 07-05-2014, 10:51 AM
longyard longyard is offline
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Rob,
I'm a big fan of Austin 7s and enjoy seeing anything related to them. I used to own a "one of one" Brooks Sussex Special" (BMW 328 style body built 1953) but had to sell it to pay college tuition for my step-sons.

Your chassis work looks impeccable. What year? Later I believe due to the turn signal brakes? Please continue to post photos as you build your body. You've made a great start.
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Old 07-05-2014, 11:58 AM
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Jere Jere is offline
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Thanks for posting Rob I'll be watching.

Jere
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Old 07-05-2014, 01:06 PM
metalman sweden metalman sweden is offline
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Very interesting and nice so far, keep the photos flow!

i will follow you with great interest
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Old 07-06-2014, 03:11 AM
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HEATNBEAT HEATNBEAT is offline
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Looks like a great start!
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  #6  
Old 07-06-2014, 04:32 AM
Cardiffrob Cardiffrob is offline
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Thanks for the comments, guys.

I'ts a 1935 car so it has got an earlier Rad shell on it, no point going for a pressed steel boring shell that it would have once worn. I had thought about shortening the shell to get a lower dashboard height but it would have meant re-chroming and I've not enough spare cash to cover that. There are just 3 weeks left before I go into hospital so it will have to be finished or sold by then. The next 6 months will be in a back brace.

Next job is the doors. I thought I'd try to have 3 90-degree pieces and a curved top piece from the top of the A-post down to the back of the door. That shouldn't be too hard to do and it won't have any other curves. It'll need skinning in Ali and I guess having it overlapping the body will be easier than flush? Any thoughts? Would you normally add a plywood skin to the door frame and then skin the plywood? I've not found any good descriptions or photos of the process.

Is it worth trying to make my own hinges or are there good sources of cheap ones from something like an industrial use? £75U.K. for a single door set over here.

I treated myself to some polishing of the outer skin this morning. Looks nice but it does start to show up all those tiny little grazes that I thought I had avoided during the bashing processes. It is 1.5mm 1050 cheapo grade material. Does it develop any sort of surface 'treatment' during manufacture? After a first polish there is a definite difference in the feel of the metal. Hard to explain other than to say that it almost looks like there is a grain showing until the top layer is polished off.

Thanks

Rob
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Old 07-07-2014, 04:15 AM
Peter Tommasini Peter Tommasini is offline
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Nicely done Rob
Peter
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  #8  
Old 07-07-2014, 02:07 PM
rewdco rewdco is offline
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Hello Rob,

I love this project! Please send more pictures! I' always wanted a Seven Ulster replica (or something similar), you're making me jealous!

Cheers,
Jan
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Old 07-07-2014, 05:29 PM
Oldnek Oldnek is offline
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Nice job so far Rob,
The last time a seen a photo of a chassis like the one you posted, was when the late great Peter Brock started out his racing career, but your one is a little more refined.
Can't wait to see your next installment.
Cheers John
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Old 07-07-2014, 07:34 PM
invision invision is offline
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Great start Rob. Looking forward to seeing more.
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