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  #141  
Old 03-10-2021, 04:39 AM
Jaroslav Jaroslav is offline
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Advice and help is needed. One head is not enough. I have a friend who will always help or advise. It's good for sorting out thoughts. But sometimes the debate is longer than the work itself. Clarifying the main points is equal to the battle. It is a friendly battle that has only one goal and that is a good result. Then we drink beer, (talk about women) and brag about how well we did it.
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  #142  
Old 03-10-2021, 10:30 PM
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racer-john racer-john is offline
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Richard:
Just tried to reach Mike's Facebook page and it appears to be unreachable. Hope he is OK.
His Austin 7 is beautiful.
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  #143  
Old 09-05-2021, 06:51 AM
skintkarter skintkarter is offline
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(Repost from the Facebook blog on the build, so apologies that some of the terms are a bit basic for AMS )

Week three of lockdown and quite a bit going on in the office with insurance claims and policy alterations. But did get a bit of time through the week to have a mess with the front transition piece where the guard meets the spoiler.

Being the Yorkshireman that I am, figured I would cut a test piece out of some of the front spoiler scrap pieces and just see how the process worked out. The further I got into prototyping the piece, the more I thought that it could be an actual production piece.

First operation was to create the step at the front where the panel lips under the spoiler. This is called a joggle and was achieved using a couple of step rolls in the swage. Took a couple of passes to get the required depth and sharpness.

The idea of doing the joggle first before cutting out the shape, was that the bit where it virtually comes down to a point would have distorted to buggery, if I had already trimmed to the curve of the front apron. Doing it this way, the panel stayed pretty flat at the front.

The curved shape (reverse) was then just a matter of forming the panel over my knee until it sat nice and flat on the buck. Bit of back and forth to get a nice fit, as there is a slight transition the further it moves away from the front apron. I was able to pull the buck away from the front panel during this phase so that again I could get the shape right without the interference from the apron, before trimming the inner curve.

The accepted way of achieving the 25mm upstand for the join to the apron, would be to 'tip' up the edge and shrink the resulting flange. I knew that with my skill level, this would not end well, so decided to 'cheat' and weld the flange on corner to corner from the back. Ended up with quite a bit of penetration on the front (right in the corner) so spent a while with the Dremel grinding this back to a bit of a radius. The painter can fix the marks...

Bit of fiddling around with the outer edge to allow it to fit up under the front spoiler and then it was time to trim and weld to the arch panel.

Preheated, tacked and then welded both sides with a tiny amount of filler, pulling the puddle along to create a fairly flat bead. I’ll dress the tops of the welds tomorrow and planish flat.

Then I can start to think about the radius on the outer edge and mating the top panel to the side panel. Radius is quite tricky, as it transitions from virtually corner to corner at the front, to about a 25mm radius at the A post.

Better not stuff it up at this point!

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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

Last edited by skintkarter; 09-05-2021 at 07:21 AM.
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  #144  
Old 09-05-2021, 09:58 AM
cliffrod cliffrod is offline
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Love seeing the progress, Richard. Maybe if you stuff it just a little against the shop door on your first excursion outside, the rest of the dents and scrapes will be a non-issue..?

Seriously, I do think about air dam builds like yours, the lower leading edges & the punishment they must endure being that close to the ground. It takes a committed man to build something like that. Very cool. My hat is off to you.
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  #145  
Old 09-05-2021, 08:37 PM
skintkarter skintkarter is offline
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Haha - thanks Cliff. There will be a leading edge of some 30mm protrusion attached to the bottom of the air dam, which will extend rearwards into a full undertray and rear diffuser - ground effect that the original cars never had. Thinking at this stage of some sort of sacrificial plastic sheet (10-12mm) or perhaps just painted ply. Should be 70mm from the deck when the car is on the ground.
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  #146  
Old 11-06-2021, 04:20 AM
skintkarter skintkarter is offline
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Well I’m apparently here, yet to succumb to the ‘flu or the bioweapon. Auckland is still in lockdown after 80 odd days, I still have half a bottle of argon, the Chardonnay stocks are holding up, I’m wearing welding goggles and there are 106 miles to Chicago…

I have been distracted a bit. A mate lightly snotted his 2003 M3 which I have coveted for more than 10 years and in a bizarre twist, the insurer paid him out the insured value and gave him the car back. We bought the car from him (still drivable) and over the last month I’ve repaired it and it should head off for paint this coming week to my mates at Eurotech Auto Repair Centre – the local BMW approved repairers. She is nice addition to the shed – NZ new, 2003, proper 6 speed, 19” rims, no sunroof and Imola red over black leather. Just 120,000 kms 😊

Anyway, got my head in the right space over the last couple of days and attacked the left front guard. The widening radius of the edge had been doing my head in.

Gave it a few passes in the swage with the two radius rolls I made, squishing the shape into a skateboard wheel lower die.

Whilst this imparts the initial shape, it’s bloody difficult to get everything in the right place and transition the radius correctly. So this morning, dropped the arch section of the buck away, annealed the edge and with a combination of a slapper, various radius dollies and a pair of modified vice grips, gradually coaxed the edge into the right shape.

Pretty happy with how it all sits now and next is to commit and trim for welding.

Tackle tomorrow when I’m sober and plan is to try and weld it with O/A.

In the immortal words of Clarkson, “What can possibly go wrong?”

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  #147  
Old 11-06-2021, 04:57 AM
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Gojeep Gojeep is offline
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Great to see you back at it Richard.
We hold the world record on lockdown days at 270!
I just exchanged three bottles of welding gas as finally out of lockdown again here in Melbourne.
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  #148  
Old 11-06-2021, 04:24 PM
skintkarter skintkarter is offline
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Cheers Marcus. I can't believe what you guys have been put through. Unfortunately Cindy and Dan are from the same mould and I suspect she won't wish to be outdone.
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