thank you for the additional info peter but why you use better quality material ( E235 +Cr1 ) for less stressed parts? and what you understand under: thick wall metric square? 1,5 mm? or thicker? but I enjoy watching your pictures how you do all
There is no mystery in the material choice. It is just because I have access to the square profiles locally and the cost difference between the slight different grades is insignificant. Also the welding characteristics are very much alike. Most of square / rectangular profiles are with 2 mm wall thickness.
I managed to squeeze a few hours of workshop activities into my weekend schedule. Got rid of the last pieces of federation add on's and straightened out both rocker panels. Happy weekend to all. Best Peter Removed the 5 kg door reinforcement bars and welded in a patch to close the hole: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Removed the rear collision protections bars: Image Unavailable, Please Login Image Unavailable, Please Login And finally straightened out the two rocker panels: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Best Peter Image Unavailable, Please Login
Finally, time for an update from SUNNY Denmark. I have managed to squeeze in some shop time between regular work, 50 years Dino celebration and beach weather and have now completed re-building of the front chassis section. This job was quite challenging with respect to accuracy but i managed to keep a very narrow tolerance using the straight bench as support and reference. I have quite a lot of respect for Newman who did the same job in free air more or less! All major front components have been installed temporarily for a final dimensional test. Next up is fixing all the fiber glass panels and spare wheel carrier. Best regards Peter Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
And a few more pictures: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Beautiful work Peter please keep posting. It is great to see all the Boxer love in this section and all the work being done around the globe to keep these cars running and looking beautiful. For those that are focused on value nothing will go more to the desirability of these cars then having these fully restored cars out and about. Thanks for posting...
Good day Peter, I echo Scott's post... Wow that is some amazing fabrication work you are doing! Well Done! Cheers, Sam
Thanks to all for the nice words! I am slowly progressing in the fiberglass department. The lower right-side wheel well inspection panel is NLA so I had to fabricate a panel using an original left side panel for inspiration. I first made a panel in aluminum and then used that to cast the new fiberglass panel. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
And then it is time for a question to the experts of the forum. Is the wheel well panel installed on top or below of the inner fender (See pictures): Best regards Peter Image Unavailable, Please Login Image Unavailable, Please Login
I took advantage of the nice autumn weather in Denmark and moved my glass fiber fabrication and bad smell outside to every bodies satisfaction. I fixed some old bad repair jobs on the used original front spoiler I was lucky to find (Thanks Paul), cut out holes for lights and radiator cooling and installed air channels for brake cooling. I had to give up on my old wheel carrier. It was in to bad a state so the decision to make a mold and cast a new one was easy. Big job but it paid out in the end. Lastly, I decided to try to fabricate the two fan covers from scratch. I think they came out nice. The easy part was the two NOS inner fenders I got from Maranello parts, it is amazing that it still is possible to find parts for these old cars. Enjoy......Best regards Peter Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
And a few more: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
It must be time for a very short update. All welding is completed, and the car is now made ready for paint. Paint will have to wait till summer and while awaiting that I have started on the smaller stuff like disassembly of parts and cleaning parts in preparation for plating. There is also time for a little fun; Decided to play a little with silicone mould making and casting in steel reinforced liquid plastic resins. It only took about an hour to produce 4 of the NLA plastic end covers for the spoiler trim. Only need some black paint to complete the casting job. Happy New Year to all Peter Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login ] Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
I love this thread. Thanks for sharing all of these details, and thanks for the inspiration. Happy new year to you.
Long time gone since last update due to trivial activities such as every day work for a living and family stuff. But the project is not completely set on halt. I completed hand cleaning of all nuts and bolts and other plated components from the entire car except the engine that will be dealt with separately. It is an enormous amount of parts to keep track of and always very exiting to send the stuff out for plating knowing that if the parts are lost the project is more or less lost as well. Anyway I got most of the yellow and blue zinc back this morning and from the weight it looks likes it is all there. I am a great believer in re-using the original hardware and I've inspected all nuts and bolts and have had less than 1% rejects, actually most components looks like new. Enjoy a few pictures from the process: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
And here is the parts returned from the plater: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Also got started on the shocks. All are in good shape except from the bushings that's shut as usual. I always prefer to install the bushings prior paint treatment to avoid scratches in the new paint: Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
I got the radiator and the condenser overhauled. Decided to differ a bit from original on the radiator and went for a newer more efficient core design. Also took the opportunity to sand blast and electro galvanize the steel frame on the radiator so corrosion from the backside should be less prone. I love to watch the old man in the radiator shop work on these old style radiators made of steel and copper while he swear over the newer stuff made by plastic and aluminum and mostly imported from China. He has been in the radiator business for more than 45 years! Paint will be added later. Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login