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  #131  
Old 09-26-2020, 07:18 AM
metalmarks metalmarks is offline
MetalShaper of the Month October 2020
 
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I'm glad you're back!
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  #132  
Old 09-26-2020, 12:51 PM
dwmh dwmh is offline
MetalShaper of the Month May 2018
 
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It's looking good Richard. Glad to see you using some of gorgeous tools you have made (bead roller for one).
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  #133  
Old 02-15-2021, 02:44 AM
skintkarter skintkarter is offline
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Crikey it's been 5 months since my last confession - I mean post! Another new sickle more suited to our local goat tracks (Multistrada 950s) a 4 day run to bed in and test same, quite a bit of wine (not concurrently) and of course the small wheel build for which January MSOTM was a totally unexpected honour. Plus we still have a fair bit of work on and as of last night, we become Stalag Luft Auckland once more with a snap Covid lockdown.

Anyway...

I'd had somewhat of a mental block re the radius on the top of the front guard sides. My Metalshaping God mate Mike Roberts had moved well down Country (I knew I was asking him too many questions) after I helped him sell his house, so working out how to impart the top radius was a challenge. The radius goes from about 30mm at the front door post, reducing over the arch and down to nothing where it all meets the splitter.

The solution was a couple of custom dies for the beadroller and some manipulation of the panel to blend the two resulting round overs. The shrinking and stretching required as the radius rose and fell over the arch performed with a hammer and stake dolly as well as an attack or two with the shrinker stretcher. Luckily I left enough on the radius to accomplish this on the RF before trimming off the now daggy bits.

Stupidly I completely forgot the extra length when doing the LF and trimmed back to almost the finished length - Doh! A function of doing the bits 2-3 months apart.

This meant a whole bunch more hammer, dolly and bending over a sandbag to get the panel to lie true to the buck again. Everytime I adjusted the radius, the panel buggered off in every unwanted direction. I think I sank a full day into making it behave again and fit the buck.

So the sides were kind of done, but the tops had nowhere to terminate and ultimately attach.

Long story short, I settled on some 25x25x1.6mm alloy box, level for the most, then angling down to the front headlamp/intercooler support panel.

The connection to the front panel could not use the M6 spire clips I'd used on the rest of the connections, so had to be M6 rivnuts. However I wanted to use the thick head ones I have for better strength.

This meant that I needed to create a small die to impart a suitable recess for the heads. Some scrap 3/4 leadbright hex I'd been carting around in my scrapbox for the last 40 years, an M8 capscrew and a bit of stepped 1040 to do the squashing. The idea being that the die could be used in situ and the bottom hex held with an open-ended spanner whilst the top die was wound in with an allen key.

Pretty happy with the result.

Next challenge were the brackets to hold the indicator units to the headlamp panels. I'd knocked up some temporary ones a few months back to enable the headlights and grille to be indexed for mounting all of the front components into the new bespoke panels. Not a great look and the lamp fixing was just a 10g self tapping screw driven through the 1.2mm bracket. They wouldn't have survived disassembly more than another couple of times and the holes would be flogged. What was needed were some new 1.6mm brackets with proper spire nuts (speed clips) for the final 8g screws. However the brackets did need a recess to allow the speed clip to lie flat. Luckily I'd already made up a die set to impart the desired squash.

Plan is to solid rivet the now 4 brackets to the headlamp panels.

So now back to the paper pattern for the top half of the guard.

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Link to our racecar project https://www.facebook.com/pages/Elan-...ab=public&view

Last edited by skintkarter; 02-15-2021 at 02:50 AM.
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  #134  
Old 02-17-2021, 04:12 AM
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Gojeep Gojeep is offline
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Nice to see you working on it again Richard.
Love the custom tooling you made to suit your needs.
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  #135  
Old 02-21-2021, 10:36 PM
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Great progress richard. Nice tool design.
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  #136  
Old 02-22-2021, 03:43 AM
skintkarter skintkarter is offline
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Cheers Marcus and John.

I'm lucky that I did my fitting and turning apprenticeship in the early 70's in NZ with a guy who had a brain the size of a planet, plus I've been privileged to end up with a mate, client and mentor who just does the most amazing stuff. Unfortunately I asked him one too many questions and he has moved 300kms away from me rather than the 5 he was previously. He has worked for the McLaren Trust here in NZ, done all of the really tricky panelwork on several warbirds and well as multiple important and historic racecars. I walked into his home workshop one day and asked what he had on the bench. What he had on the bench was the firewall from Bruce McLaren's own Can-Am car which had been crashed. Gather it was a job via the US, but he was insistent on recovering it rather than just making a new one. He could show me where in 1968 it was modified with different master cylinders. Making a new one would lose that originality, so he quietly worked away for a few weeks and sorted it to his satisfaction.

One of his previous projects was a nut and bolt replica of a Cologne Capri. Client had sourced 2x brand new bare GA engines from South Africa. Apart from all of the 4 link stuff and wheel tubs, Mike made all of the engine and gearbox mounts as well as the headers, complete with the flat 3 collectors either side. He just made a rubber lined die to press the halves from 1.6 ms.

Current project is a Meteor engined Bentley racecar for the same owner.

He also has his own Austin 7 Special on the go in the style of a Mercedes Silver Arrows from 1938

God I hate him...

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"I know nothing. I from Barcelona" (Manuel - Fawlty Towers)
Link to our racecar project https://www.facebook.com/pages/Elan-...ab=public&view
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  #137  
Old 02-22-2021, 02:53 PM
Gareth Davies Gareth Davies is offline
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Those triple IDA’s are an unusual addition to a Rolls Royce engine. Nice project though.
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  #138  
Old 02-23-2021, 02:37 AM
skintkarter skintkarter is offline
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Apparently worth a bomb to an old Porsche owner - but the owner of the Bentley is err, quite well heeled shall we say
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"I know nothing. I from Barcelona" (Manuel - Fawlty Towers)
Link to our racecar project https://www.facebook.com/pages/Elan-...ab=public&view
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  #139  
Old 03-09-2021, 03:40 AM
skintkarter skintkarter is offline
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Ran out of talent, so called in the cavalry.

Trouble with all this metalshaping stuff is that I don't yet have a bank of failures stored in memory.

My first thought with the guard top was to cut the blank and shove it through the slip rolls to get the rounded shape for the arch, then bend up the back bit to sit flat on the buck where it meets the door post.

All well and good if there were no shape in the top of the panel.

The panel actually has a flat bit under the bonnet and then the outside angles down to give a bit of shape to the flare. Probably a good 10 mm overall.

Hmmm... Okay so I need to wheel in the centre to raise up the middle and leave the edges down. This starts to work, but the bend I'd put in the rear of the part was locking in the shape.

Doh!

Admitted defeat and called in the cavalry in the form of local uber aircraft restorer, Rob McNair. Who of course bowled up in his mint previous 1 owner E-Type done just 60,000 miles and NZ new.

Pause to vomit.

Rob quickly assessed the situation, flattened our my bend, wheeled some shape in the middle and then rebent the return
.
Within 45 minutes he had the panel sitting much better.

Used the big wheeling machine for the lower crown and then the new small machine to stretch the edges of the bend area to effectively raise the centre.

I've spent another 2 hours on it creeping up on the final shape and plan is now to trim the outside edge and turn the outer radius.

Well at least that is the theory... 🙂

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"I know nothing. I from Barcelona" (Manuel - Fawlty Towers)
Link to our racecar project https://www.facebook.com/pages/Elan-...ab=public&view
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  #140  
Old 03-10-2021, 04:22 AM
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Gojeep Gojeep is offline
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Always good to have someone to fall back upon.
Peter Tommasini has always offered to drop around if I ever get stuck. Not had to do it yet, but has helped mentally knowing there was a way out.
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