Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
|
|
so, I did a bit more this evening. I ended up doing a bit I wasnt planning on doing at all, I wanted to work on either the steering or rear axle brackets but ended up making the firewall instead! but I suppose it needed doing anyway, and its all progress. the firewall has been annoying me for while, as I was trying to keep it in the stock position, but ive now cut so much of it out for various bits,(clutch lever, bellhousing, dizzy) its pretty much impossible to do so. so I decided to make things a hell of a lot easier for myself and recess it. it now mounts to the backside of the steering/brake uprights, which means its recessed about 4.5" this gives it enough depth over the gearbox for it to be one piece, unlike the small bits I was left with with it mounted further forwards. first thing I had to do was get the cowl side panels held in place solidly so I could work to them. I had previously been relying on the cowl top for their alignment, but I needed to remove that so I could get into work, so 2 simple braces made from 1/2 angle were welded to the rearmost exhaust bolts (as they can simply be replaced when I'm done) then tacked to the edges of the lower cowl panels,w ith the cowl top in place. then I could unbolt the cowl top and the sides stay in the right place. ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00042.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00043.jpg[/IMG] then, I mocked the new firewall up in card, and then hardboard. this took ages! loads of marking, trimming, marking, trimming, etc. to get a good fit and mark the location of various components. once it was to a stage I was happy with, I transferred the measurements to a sheet of 18ga (1.2mm) steel, and cut it out. you can see the basic shape is the curve of the cowl at the top, with the curve of the tunnel clearing the bellhousing at the bottom, the starter motor bulge cutout on the right, and the lower left side is slightly shorter to clear the clutch arm, then a hole drilled for the steering shaft. ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00047.jpg[/IMG] so once it was all cut out, I then drew some arty farty lines on it, all measured so they curved nicely and were equidistant from all edges (yes I'm a pedant when it comes to things like this) ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00048.jpg[/IMG] then, with the assistance of choppy (who's arm you can see there, pretending hes down wid da kidz), we fed it through the bead roller. choppy was wheel man, ensuring he was turning the wheel at a constant speed, as I fed it in. I used the 1/4" step dies, so the whole centre section is now recessed in relation to the edge. like so- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00049.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00050.jpg[/IMG] I forgot to take a pic of it done, but I then chucked it in to see how it looked. pretty nice I recon- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00053.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00054.jpg[/IMG] but thats not the whole story. oh no. next, I need to edge it, for extra stiffness so it doesnt boom, and so its got a flange to mount the tunnel and floor to. so out it comes to have the two bottom edges folded over, that had to be done in an improvised way in the vice to prevent damage to the swaged areas- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00056.jpg[/IMG] then, I wrapped a length of 2mmx12mm(or 1/2" in real money) steel strap around the argon bottle of the welder, as it turned out just about right to edge the centre curve- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00057.jpg[/IMG] it was then tacked on everyone", ensuring the curve was good and even and lined up with the panel edge nicely, then tacked everyone/2", then the gaps filled up, and it all flapwheeled down- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00058.jpg[/IMG] the same was then done to the starter motor cutout, and then we have the more or less finished article. none of the other edges will need edging like this. looks pretty flash I think youll agree- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00059.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00060.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00061.jpg[/IMG] and slotted into place and held into the correct position with a few TEK screws. theyll be replaced with rivnuts and bolts once the other bits are in around it- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00062.jpg[/IMG] and thats job jobbed. it now means I can start figuring out where my other bits of floor and tunnel are going, so I can start locating the controls- pedals, shifter etc. |
| |
Last Edit: Jun 12, 2011 16:45:25 GMT by Dez
|
|
|
|
slater
Club Retro Rides Member
Posts: 6,390
Club RR Member Number: 78
|
|
Mar 18, 2010 10:14:09 GMT
|
|
nice to see you back on the case dude!
|
| |
|
|
rob0r
East of England
Posts: 2,743
Club RR Member Number: 104
|
|
Mar 18, 2010 11:48:25 GMT
|
|
Tidy work!
|
| |
E30 320i 3.5 - E23 730 - E3 3.0si - E21 316 M42 - E32 750i
ETC
|
|
Chris™
Part of things
This is clearly filler material.
Posts: 519
|
|
Mar 18, 2010 16:18:53 GMT
|
|
Fantastic, just settled down with a pork pie and a drink and caught up on all the updates ;D Skilled craftsmanship indeed and a very enjoyable thread!
|
| |
Last Edit: Mar 18, 2010 16:19:10 GMT by Chris™
1989 Volvo 340
1986 Suzuki SJ413
2000 BMW 318ti
2006 Lexus IS250
|
|
remmoc
Part of things
Posts: 931
Member is Online
|
|
Mar 18, 2010 18:22:42 GMT
|
|
Really enjoy reading this thread , great workmanship , Ive not much to comment on , just to say I'm still here and still reading with great interest
|
| |
|
|
|
|
|
Mar 18, 2010 20:08:28 GMT
|
|
Lovely neat work and a joy to behold
|
| |
|
|
|
|
|
Mar 18, 2010 23:31:14 GMT
|
|
that's a nice bead roller you have there, any more detailed pics of it....?
|
| |
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
|
|
slater, its good to be back working on it  cheers rob, ile try to get yours as neat too  chris, send me some of that pork pie this way, lol! remmoc, good to see your still along for the read tony, thanks, its nice to get a 1-up from someone who 'knows' metal. it must mean I'm half decent too stephan, no I havent at the minute, but I can get some. tbh, I never finished it, it still needs some work to be 'right' but its finished enough to work so it just gets used how it is. its actually a much modifed off the shelf vice-mount item I bought about 6-7 years ago, it was about 200 quid back then with about 7 sets of dies. the steering wheel(that replaced the crank handle it came with, much more controllable) is off a '50s ford based special, the main upright is a ford pop torque tube, the adjuster handle was made from a broken G-clamp, and the (bent) modular wheel that forms the base is off a ford galaxie stock car!! I think your interest may prompt me to get my ass in gear and finish it off and post up some fresh pics of it all done.  |
| |
Last Edit: Mar 19, 2010 0:32:42 GMT by Dez
|
|
|
|
|
Mar 19, 2010 16:39:01 GMT
|
no worries, not a mega hurry just want to make one at some point. it seems to be a good design, i noticed the steering wheel, may have to get mine made now also. |
| |
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
Mar 23, 2010 22:12:16 GMT
|
time for 'nother update. this update kinda follows on from the one above, in that it pertains to the shaping of the tunnel. after I made the firewall with the constant radius on the bottom for the tunnel, I decided that the loop id put in over the gearbox at the A pillar just wasnt right. the flat topped shape clashed with everything else down the centreline of the car, which all had nice smooth radius arches. plus it would making cutting and shaping the tunnel to go over it a right ballache. sometimes you just gotta man up and admit its not right, and throw it away and start again. so I cut it out and binned it  then I measured up and made up a template- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00970.jpg[/IMG] 6" radius, a fraction smaller than the 7" radius at the firewall, so the tunnel would have a slight taper. then, a bit of maths to figure out how long the bit of metal would need to be (Pi x D divided by 2, plus an inch and a half to make it up to a nice round number so I had a bit of overlap to work with) here it is with a coat of white primer put over it in my turbo paint drying booth ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00972.jpg[/IMG] then, I marked it out to cut. 3 sides, everyone/4". that 77 lines to cut, accurately for an even curve!! drawing the lines was bad enough....... marked out- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00973.jpg[/IMG] cut, mega cramp in my arm after holding the grinder for doing this- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00974.jpg[/IMG] all floppy!! then, bent round the template with a few screws to hold it in the right place- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00975.jpg[/IMG] then, weld the sh1t out of it- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00976.jpg[/IMG] and flapwheel it to within a inch of its life, and radius the edges/final finish with a file, ta daa- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00977.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00978.jpg[/IMG] then, I had to fit it into the gap id made. I didnt take a proper pic, but id left the right hand side upright on as it was in the right place, I just cut the top down and tacked that side on, then where id cut out all the bottom corner on this side I had a big gap- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00993.jpg[/IMG] so I cut some bits to go in. notice this side has to slope out to clear the bulge on the side of the gearbox, and I had to redo the angle joint at the bottom as it was different to before- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00994.jpg[/IMG] |
| |
Last Edit: Jun 12, 2011 16:42:26 GMT by Dez
|
|
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
Mar 23, 2010 22:52:09 GMT
|
so I buzzed those bits in, then remade the framing to the rear of the gearbox under the floor too, I made it all square rather than the curves, to simplify things and make it easier to mount a couple of things- which youll see when I get that far. also notice I moved the framing out an inch each side so its to the outside the tunnel loop rather than in line with it. again, this is to allow easier mounting of the panels once fitted. all done- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00995.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00996.jpg[/IMG] then, the last bit I had to sort out before I can set to making the actual tunnel panel is the shifter. the combination of big channel +chassis Z, high mounted gearbox/motor, toploader truck gearbox and big dash meant this was always going to be a rediculous shape! first I had to cut a big chunk out of the bottom of the dash for clearance. this will be tunnelled and the dash brace re-enforced once I know its the right shape. ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00997.jpg[/IMG] then, it was time to break out the oxy torch with the cutting head on, for some serious heat to get nice bends on the 7/8" dia shifter. I have to admit I love using the oxy torch for shaping stuff (hence the rose I made for my Gf for christmas). ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00998.jpg[/IMG] much trial and error later, and about the 12th attempt, I got it right, so I can select all gear without it touching anything, and still being a pleasing shape. that was after quite a bit of f-king about to get the gearbox out of reverse that it had somehow selected by itself with the shifter out! ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC00999.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01000.jpg[/IMG] thats the original '53 f100 shifter ive used, which is nice cos it tapers out along its length from approx 3/4" at the bottom to under 1/2" at the top, so its a nice shape. |
| |
Last Edit: Jun 12, 2011 16:40:15 GMT by Dez
|
|
|
|
|
Mar 23, 2010 23:19:25 GMT
|
|
Dez,
your thread is one of the reasons i reciently signed up here, thanks for taking the time to share your build, looking mighty fine.
A few years back i created a similar curve in some square box section, i used a wheel as a former clamped it in the vice and pulled it round by hand, admittidly the inside wall hollowed in a little and the sides required squaring in the vice afterwards, but i was pleased with the outcome.
Anyway keep the updates coming, this is inspirational stuff.
|
| |
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
Mar 23, 2010 23:20:40 GMT
|
youve probably also noticed all the scribble on the glovebox lid, where I was trying to figure out what the hell the shift pattern was!! this was mostly cos I didnt know weather the box was a 3 or 4 spd. it turns out its a 4spd(i think!!), which is a bit of a bonus! then, I took the shifter off, and went over it with a file to remove all the toolmarks and slaking/burnt paint from it being heated, and finish it all up nicely. I then delved into my knob collection heres the options- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01001.jpg[/IMG] left, crazy cast brass 'finger'! was originally the jockey shift off a chopper, genuine period article cast in california in the '60s. how cool?! I don't think it suits it though. second is a standard-ish '60s black truck 'knob, knurled ring with the shift pattern in the top (which is correct as its off my spare gearbox which is from a later truck). decent size and comfy. third is the original f100 knob, its a weird cloudy white plastic that looks a bit like bone, which I really like but its a bit too small to look right. lastly is the red knob off a landy transfer box lever, again a bit small. for the minute, ive put the black one on as I like that best, but I will eventually be running a custom one made up of the second and third knob with some inlay bits on it. finished job- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01002.jpg[/IMG] ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01003.jpg[/IMG] I can still open the glovebox with it in first gear, and can get all the gears without it hitting the dash or anything, and I'm pleased with the shape, height and position- nicely curved, tall without being silly, and easy to reach. the shift action aint exactly amazing compared to anything modern, youre definately stirring the gears a bit and I don't think really rapid shifts will be possible (it was acceptable in the '40s, lol!), especially as I think the box is non-synchro. the only thing I might do is file up the anti-twist slot on the side of the shifter base til its square again, then drill the box and put an oversize pin it to tighten up the 60 years of wear there. and as a last little bonus for today, I finally got round to capping off the left hand end of the dash to match the other end id already done. this was born out of a conversation with a mate who pointed out I would look a lot more finished if id finished all the little jobs id started and only done one side of!! (which is very true, my excuse is I kept having to leave it to work on other peoples stuff so the other side never got done) so, end of dash marked up and trimmed down to match the shape of the other side- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01004.jpg[/IMG] then a plate cut a bit oversize- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01005.jpg[/IMG] then it was flapwheeled down to perfect size and tacked as a went along, then flapwheeled and filed up to shape til it was all nice and smooth. like so- ![]() img.photobucket.com/albums/v617/dezaster/A sedan/DSC01006.jpg[/IMG] I really need to do the other little bits on the dash and get it finished off and in primer really. that might be the next job, we'll see how it goes. |
| |
Last Edit: Jun 12, 2011 16:38:03 GMT by Dez
|
|
Mike
East Midlands
Posts: 3,387
|
|
Mar 23, 2010 23:36:51 GMT
|
|
Some fantastic work there Dez, this thread is a great read.
|
| |
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
Mar 23, 2010 23:38:54 GMT
|
Dez, your thread is one of the reasons I reciently signed up here, thanks for taking the time to share your build, looking mighty fine. A few years back I created a similar curve in some square box section, I used a wheel as a former clamped it in the vice and pulled it round by hand, admittidly the inside wall hollowed in a little and the sides required squaring in the vice afterwards, but I was pleased with the outcome. Anyway keep the updates coming, this is inspirational stuff. thanks for the kind words mate- nice to know its my fault youve been dragged into here lol ive done similar experiments of bending tube how you say, with mixed results. rule of thumb is the thicker the wall, the better it works, but i found for what I'm doing and how tight the bends are, this method gives much better results as i really need all sides to be square. |
| |
|
|
v8jim
Posted a lot
Posts: 1,304
|
|
Mar 28, 2010 20:34:05 GMT
|
|
i can honestly say this is the best thread i've read on here and i've learnt so much just reading it.
when i clear out my garage after easter and start on my model A again i plan to bin a lot of stuff and redo it all.
thanks for the insperation get cracking again and improve my quite basic metal working skills
|
| |
Max sig pic size: 80px
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
|
|
well jim, ive learnt a lot doing it too! ive lost count of how many times now ive decided i just couldnt live with certain bits being how they were, and redone them. its happened again over the last few days, (and is going to be happening some more, ive got a list of bits I'm not happy with)- ive redone my door latch install for the third or possibly 4th time! I'm about happy with it now though, so thatll be covered in an update soon, once ive filled in a few gaps to finish it off. i got the shifter 'tunnel'/ dash framework done over the top of the shifter too, thats turned out nice and really finished the dash off, so one evening this week ile update on that too. then itll be more finishing up of part-done bits til they're all caught up with- thats if people stop throwing money at me to do their cars first! |
| |
|
|
v8jim
Posted a lot
Posts: 1,304
|
|
Mar 31, 2010 21:22:30 GMT
|
|
going to bin my gearbox xmember wich it poo anyway and try and make a nice curved one even though hardly anyone will ever see it.
|
| |
Max sig pic size: 80px
|
|
|
|
|
|
|
Epic thread Dez, just reread the first 12 pages that I'd already seen and caught up with the new stuff  props to the time and skill you've put in, dash looks really nice in there with the new shift rod, any pics of the headlights on yet? also, super cool 52? beetle coming along in the background  |
| |
|
|
Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,790
Club RR Member Number: 34
|
|
|
|
jim, thats one bit ive not updated as its hidden well under the car, ive got a pretty funky crossmember going on too, with the mounts recessed into it for max ground clearance! i need to finish it off with proper side mounts though to make it removable, as its only tacked in at the mo to keep it in the right place. and its not about who sees it, its knowing its right cheers stu, yeah its been a lot of work! no pics with lights yet, as I'm waiting to get some more ('20s french deco styled items) back from the silversmith whos repairing them. the bug is a crotch cooler, so '51-1/2, six month only model. that build is easily crazier than this one though, mid mounted mr2 turbo motor, narrowed mx5 front clip, r32 GTR brakes, and I'm responsible for the rather elaborate one-off chassis holding it all together the owner is on here, but i think theres a build thread on DW. update in a min or two folks |
| |
|
|
|
|
props to the time and skill you've put in, dash looks really nice in there with the new shift rod, any pics of the headlights on yet? 