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  #21  
Old 04-06-2021, 05:10 AM
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Nice work on that lower door pillar.
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  #22  
Old 04-06-2021, 05:19 AM
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Quote:
Originally Posted by chrisnz View Post
Door proportions look spot on, nice work!
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  #23  
Old 04-07-2021, 12:23 PM
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Quote:
Originally Posted by Gojeep View Post
Nice work on that lower door pillar.
Thanks Marcus.
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  #24  
Old 04-07-2021, 12:24 PM
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Door proportions look spot on, nice work!
Thanks Robert
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  #25  
Old 04-07-2021, 01:17 PM
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These bodies had a sill and swage in the lower rear panel. I will be deleting these features as I go forward. The reason to do this is because the body is being channeled, which moves the body and running board closer together and I gain 40mm by losing them. I made a new rear panel weeks earlier while some of the parts were in the citric acid. I made the panel in 5 pieces
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The rear corners were wheeled up using 3 templates for guidance

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The top beltline was initially swaged to get a line, then transferred into the Faximil nibbler to finish

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Cut an MDF pattern to use in the press

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  #26  
Old 04-08-2021, 05:04 AM
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You are doing well with that zinc coated black steel. It is notoriously difficult to shape. CRS, cold roller steel, is much easier.
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  #27  
Old 04-08-2021, 12:28 PM
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Originally Posted by Gojeep View Post
You are doing well with that zinc coated black steel. It is notoriously difficult to shape. CRS, cold roller steel, is much easier.
The sheets I use are cold rolled but are electro-galvanized to give them better corrosion resistance, so forming is probably no different than uncoated
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  #28  
Old 04-08-2021, 10:19 PM
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Made a paper pattern of the upper beltline area. The factory has the join here, so I copied it. There was a fair bit of rust in the original piece and when I do the roof chop it will make it easier to join.
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Started with swaging along the line to give the panel some shape before it went into the nibbler. Had to make another set of dies, as this top profile is different from the bottom
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Sent the two panels to the local panel beater so they could spot weld them together

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Last edited by chrisnz; 04-09-2021 at 12:18 AM.
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  #29  
Old 04-09-2021, 05:30 AM
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Originally Posted by chrisnz View Post
The sheets I use are cold rolled but are electro-galvanized to give them better corrosion resistance, so forming is probably no different than uncoated
The coated sheets we have are not CRS unfortunately.
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  #30  
Old 04-13-2021, 05:38 PM
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Moved onto the door skins. As the original skin was off, it was relatively simple to check the shape against the frame as I was wheeling it up. Once I was happy that I had enough shape, I swaged a guideline onto the skin then made some formers for the nibbler and then had to free hand the skin through the nibbler to get the beltline swage. A bit of work with a bolster straightened the line up.

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I decided to put the join above the beltline to hopefully avoid to much distortion. I discovered that the original stamped skins were .07mm thick compared to the 1.2mm I was replacing it with. The strength must be in the shape to be so thin.

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Completed skin filed up. As I was adapting the XJ6 Jaguar exterior door handles, a small stamped profile was put into the skin to create a flat surface for the handle

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Had to modify the handles interior mechanism as it was too wide for door frame. Top handle is the original.


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