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Old 04-04-2012, 10:26 AM
www.kustomgarage.com.au's Avatar
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Default Baileigh 2012 Contest -- 1933 D8 Delage K.G. Special

Hey Guys I thought it was time to share a project with you all.

1933 D8 Delage, it is loosely based on a 1935 type 135.s Delahaye. It is an all Aluminium Body made from 1.6mm thick 5005 H34. I will do my best to talk through the photo's as I go, I didn't take alot of pictures at the start but as it progressed I took alot more.


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This is how the car was delivered to us, I spent some time going over the timber frame with body sweeps to get it to flow better shaving off some timber here and there before we started shaping the body.


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The body was shaped from the scuttle back welding it all with the T.I.G.


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At this stage the scuttle was clamped and anealed in position and turned over the timber all the way around to the top of the dash. Sorry I wish I had more photo's of this as it is quite an ask for the Aluminium to go all the way around, care is needed not to tear the metal. I do have better shots of when the back of the car is done the same way.


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The scuttle and doors finished nailed to the timber note the lower sill section at the rear of the doors will not be welded, but the tail will overlap at this point creating what is called a Fatigue Break.
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Last edited by www.kustomgarage.com.au; 04-13-2012 at 10:25 AM.
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Old 04-04-2012, 11:39 AM
ojh ojh is offline
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That is some nice work, very clean. What timber did you use for the framework, it is looks yellowish.
Do you welt over the timber before tacking the skin? or does it go direct? What about contraction/expansion of the skin when it is finished and sitting in the sunlight, seems that much aluminum would need to move around quite a bit so is it something you deal with?
Thanks, oj
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Old 04-04-2012, 04:52 PM
Peter Tommasini Peter Tommasini is offline
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Very nice job Jamie as allways....
Peter
PS "We need to set a date for the Melbourne Meet at some stage...."
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Old 04-05-2012, 04:15 AM
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ojh,
Thanks for the compliment, I did not make this timber frame but I think it is White Ash. The skin is directly over the timber, the timber is coated with boat coat. Dissimilar materials expand and contract at different rates but it has never posed a problem that I know of.


Thanks Pete, yes we do need to set that date.
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Old 04-05-2012, 06:36 AM
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Kerry Pinkerton Kerry Pinkerton is offline
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Jamie, this is a WONDERFUL project. Please take and post lots and LOTS of photos if you can. The more detailed the better. Are you making fenders also?
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Old 04-05-2012, 06:47 AM
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A 'real' coachbuilt body? i didnt think there was still anyone out there who could do the timberwork, the metal i know because i`ve seen it here and elsewhere but the timberwork is a whole other ballgame, that is gorgeous
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Old 04-06-2012, 08:33 AM
mariod mariod is offline
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Very nice work. Now that's a pefect wooden structure i wish i had one this good on the Stutz .....
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Old 04-06-2012, 10:35 AM
Nate Lagler Nate Lagler is offline
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Looks awesome Jamie, can't wait to see more!
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Old 04-09-2012, 10:08 AM
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Quote:
Originally Posted by kerry pinkerton View Post
jamie, this is a wonderful project. Please take and post lots and lots of photos if you can. The more detailed the better. Are you making fenders also?
Kerry, I will do my best with the photo's and yes fenders were made also.

Quote:
Originally Posted by troppo View Post
A 'real' coachbuilt body? i didnt think there was still anyone out there who could do the timberwork, the metal i know because i`ve seen it here and elsewhere but the timberwork is a whole other ballgame, that is gorgeous
Troppo, your rite, the timber is a whole nother ballgame as the better the frame the easier it is to pattern and shape the body skin. This particular timber frame was supplied to me by the owner, but I normally work with Jeff Edwards of Artisan Coachworks who does a magic job with timber. www.coachbuilders.com.au


Quote:
Originally Posted by mariod View Post
Very nice work. Now that's a pefect wooden structure i wish i had one this good on the Stutz .....
Thanks Mariod.


Quote:
Originally Posted by Nate View Post
Looks awesome Jamie, can't wait to see more!
Thanks Nate.



Ok on to the tail of the body.
Starting with the top centre part, my Wife Stella and myself wheeled in the appropriate shape before moving to the shoulders.


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Stella then pulled a pattern off the shoulder of the frame before laying it out on the aluminium sheet.

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When cutting out the parts to be shaped we always leave a good amount of excess just in case the part may fit better in a different position after being shaped.

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The shoulders left and right clamped in position after Stella blocked and wheeled the correct shape.

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When clamped in the right position screws are used to ensure a good fit, then datums are marked for welding and scribing of the cut line off one part to the other.

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In the above photo you can see the datum marks overlapping the weld.

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After alot of welding, dressing out the welds and file finishing it was time for more patterns.
Note with this part I was trying to keep the welds in the flat areas and not in any returns.


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I chose to turn the lower flange of this section over the timber before welding to the upper part.


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Once I had all the parts welded together it was time to turn the skin onto the frame and nail it off...

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This section was anealed before turning over and care taken not to tear the Aluminium.

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Aluminium nailed off to timber and ready for next stage...

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Last edited by www.kustomgarage.com.au; 04-13-2012 at 10:26 AM.
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  #10  
Old 04-09-2012, 11:00 AM
Bob Bob is offline
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Wow Jamie,

That's really nice and something you should be very proud of. Awesome looking car too. Got a question for you. What did the area I highlited in the pic below look like before you turned the flange? That is if the highlite shows up for you, if not, it's the area where the cove runs out near the front of the panel.

Also, how did you form the cove?

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