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  1. #1041
    Official RnS Addict legendlives's Avatar
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    Tunnel Vision.....

    Remember the transmission tunnel?



    It was lovely, wasn't it? Resplendent in it's padded and trimmed glory it was the first part of the car to be 'finished'.
    Nah. Didn't like it.
    It didn't fit nicely, and the trimming job wasn't as 'professional' as I want. Even though this will undoubtedly end up as a race only car (due to the draconian hoops that have to be jumped through and paid for here in NZ) there's no need for second best is there?

    So I ripped off all of the trim, added between 10mm and 15mm around the bottom, extended the rear and modified the trim frame to suit, moved the Dzus brackets on the chassis and generally beat it about a bit.



    The mod to the rear is purely aesthetic. It now follows the curve of the rear panel. You can still see the original rivet holes.



    One of the mods to the frame was a small extension to the driver's flange (ooo-errr missus!) to fit /seal better with the floor panel.



    Now all I have to do is get out the spray adhesive and the sewing machine and finish it again!
    (Oh, and decide on a colour/finish for the frame as I'm not 100% on the black.....)

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  3. #1042
    Rods 'n' Sods Junkie 69 ford's Avatar
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    No point in getting the sewing machine out, you'll only rip it all off again, paint it red oxide - allways good for future mods.

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  5. #1043
    Official RnS Addict legendlives's Avatar
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    One last big push at the front....

    Bear with me, good reader, for I am about to tell a tale. A tale four years in the making, a tale of pain and suffering, of disappointment, of perseverance and ultimately of achievement.
    I give you 'Primer suspect', or 'Bondo Dog Doo-Dah', or 'Fun with Fibreglass'. The front end of Cheatin' The Reaper is a hair away from being finished!

    4 years ago I was over the moon that someone wanted to swap the original front-end 'tins' for a one-piece fibreglass front.
    Here it is, still in the van immediately after collection:



    Upon initial stripping it was evident that someone had riveted steel Pop grille and side-vent sections onto the front, along with a strengthening structure obviously designed by Isembard Kingdom Brunel when he was experimenting with cast iron:







    On to the first 'total waste of time'. Filling the side vent holes:



    I always wanted separate bonnet for the flip-front as I didn't want to keep chipping the paint!



    And whilst I was at it I made up return flanges, and then glassed them into place:





    Total waste of time 2: Trying to make the bonnet fit. I suspect that the front was moulded off a damaged car as it was at least 40mm different side-to-side.
    The bulge was also an unnecessary distraction as that too would ultimately find solace in a skip.





    Then I discovered that I needed to widen the whole thing about 50mm each side. This turned out to be a blessing as whilst the outer sections were off I made them match each other by riveting them together (cut, grind, laminate, repeat.). After that it was relatively simple to get the front inners to match the outers (more cut, grind, laminate, repeat.)





    By 2019 the shape was more-or-less right, and with the addition of the new ally bonnet, and correct shaped side panels it nearly fitted:





    It just needed a couple of semi-circular divots to clear the cam-covers of the exceptionally wide engine:



    So this week I had a few days off and set to. Tidied up all of the lines and edges, then blew some primer at it!
    (Ironically it's been clear, dry weather for a week, but as soon as I hooked up the spray gun it started to spit - bugger!)





    Definitely looks like a hot rod now, and that's the worst bit of the body done!



    Thanks for reading / staying awake / not vomiting (delete as applicable).

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  8. #1044
    Official RnS Addict mygasser's Avatar
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    mygasser is online now
    i feel your pain with the secondhand 'glass front. i did the same with my anglia gasser and probably spent 3 times the cost of a new one in hours making the old one fit and not have cracks etc all over.
    yours is looking great now though so i guess it was all worth it
    neil.
    need a job done on your project? i may be able to help.

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  10. #1045
    Official RnS Addict ivanhoew's Avatar
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    really hope that somehow this can be rd legal , seeing that hooning up behind a car on the motorway would be huge fun .

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  12. #1046
    Official RnS Addict legendlives's Avatar
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    Quote Originally Posted by ivanhoew View Post
    really hope that somehow this can be rd legal , seeing that hooning up behind a car on the motorway would be huge fun .
    It would be nice.
    I've built it with all of the necessary road legality in mind - washers, wipers, lights, indicators, handbrake etc., but the certification process here is an absolute (and expensive) nightmare. Just getting it through the process would cost me more than the entire build has cost, so it will probably be just a nice race car (with the occasional accidental road mile or two....).

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  14. #1047
    Official RnS Addict legendlives's Avatar
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    Fluid thinking......

    Brake and clutch fluid that is.

    I need to get the three brake/clutch fluid pipes (which will be 1/4" OD tubes) down the bulkhead from the reservoir, then turn 90 degrees through the bulkhead at floor level.



    The easy solution would be to buy three 90 degree -4AN bulkhead fittings and nuts and simply drill three holes, but have you seen the price of that stuff? Just those three assemblies would have cost me north of $120 which does not fall within the budget restraints of this build (Yes, I'm tight!).

    My local speedshop (which happens to be the company I work for) have a stock of these fittings:



    These are old-stock, and priced to get rid of at $4NZ each + tax. Result!. I just had to work out a way of using them.
    Rifling through the fab-room bin I found a 1/2 cut length of 35mm alloy tube, which after a deal of bending, shaping and metal glue looked like this:



    More sanding and shaping I drilled 3 slightly too small holes and pressed the fittings in place, then half-welded them for support:





    There's now plenty of clearance on both sides for the -4 nuts.



    A bit more cleaning and with some drillage I ended up with this steam-punky looking thing which suits the age of the car perfectly



    It will sit at the bottom of the driver's side bulkhead so will never be seen anyway!
    Last edited by legendlives; 21-11-2020 at 07:57.

  15. #1048
    Official RnS Addict ivanhoew's Avatar
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    triffic !

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  17. #1049
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    Never been a fan of the bright blue/red fittings - expensive and garish but I discovered, quite be chance, that when you weld them they turn into a really nice bronzy/grey colour (not unlike those).

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  19. #1050
    Official RnS Addict legendlives's Avatar
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    Brake dancing.....

    The hydraulic handbrake bracketry has already appeared on these hallowed virtual pages way back. It was actually made for the ill-fated Escort project but I never finished the set-up.
    Mounting plate for it has already been incorporated into the chassis so the hard work is done.

    After purchasing (another) new master cylinder (work nicked the first one to make a pressure test rig), I found a female rose-joint with the correct thread and offered everything up. It was immediately obvious that the cylinder would need to be spaced out a bit (a lot!).



    A couple of 30mm long x 20mm diameter aluminium bosses were made and tapped through M8. These are secured by countersunk SS screws on the inside.



    And normal cap-heads on the cylinder side (though these will be replaced by Stainless bolts in the final build).



    With the (slightly modified Mk1 Escort) lever in the full-on position, the adjustable pushrod sits horizontal.



    That hideous rosejoint bolt will also get binned in favour of a stainless part.
    Surprisingly, even being 30mm longer than expected the assembly still fits without modification necessary - Phew!

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