Hi Mark, Nothing much done for about three weeks, I have been filling in pin holes and grinding back welds as well as gardening duties, fence painting in between rain and snow showers. I will get back to it next week.
Carrying on with the rear wings, they had a bit of a gap at the rear of each side, drivers side shown here.
I was going to cut and re-make the flange on the wings, but looking more at the car I saw it was the metalwork at the bottom of the valance that was too wide. This has all been replaced in the past and the end corners have been welded on at slightly the wrong angle which pushed the bottom of the wings outwards.
So......choppity chop.......new metal made for the return flange, a slice made in the rear wing and welded up again in approximately the correct position. All the big blobs of braze caused all sorts of problems welding it up again, so not the prettiest but its all solid metal again.
Same for the passenger side, you can see where I reshaped the wing into the correct position it has split the original weld where the repair section was welded on.
New metal added to complete the wing flange and the split all welded up in the correct shape.
A quick bit of filler skimmed on the drivers side (not flatted off properly here) and the gap is almost gone.
Passenger side is very good now (wing piping will fill the gap on the finished car) Phil will appreciate how much better this gap is compared to how we had it yesterday.
No, I've not been eating wine gums or eccles cakes for 3 days, though I did have a lot of birthday cake on Monday
Still been filling & sanding, though I had to scrape a load of filler off the roof again. Had some issues with the the last mix of filler clogging the paper a bit so I'd been experimenting with the amount of hardener in it. I assumed like most of us that I had been putting too much in the filler, so I had reduced it a bit to see if it was better.
The answer to that was no! it had not cured properly, so had to be removed. Turns out that I needed to add more hardener, not less. Tried a couple of mixes tonight with more hardener, and it now sands like it should.
So, what progress is there?
This is the new filler on the roof, second skim shown so hopefully when this is flatted off it will be done.
door jambs are all getting profiled all round - a small section shown here;
Rear corners are getting nearer;
So the gaps are getting tighter on the wings, still some work to go on them though.
Passenger door rear edge is getting some filler - for some reason it had quite a few small dents in the bottom, plus I have welded the window channel back on where it has come away from the door.
And I've been chopping up Phil's nice new wings
Temp mock up shows the gap required,
It also shows that not only does it need lengthening, but also it needs pulling back as the arch profile is not tight enough to fit the car, I had to do exactly the same on my arches so I guess the mould is not quite the right shape.
Hi Mark, I finally got around to reading your post, if only from about page 180. I’m not one for reading threads generally. Very impressed by your own car and the work you’ve done on the rainbow. It’s always a problem deciding how far to go, particularly on someone else’s car. Mission creep is hard to avoid though. Thanks for all your encouragement on my project also. Cheers Garry
Just building up the back of the lower sections of wing as I need to grind away the raised bead where it tucks behind the sill and at the moment there is not enough glass there to do this. The wing needs more flange - ooh-err mrs! - as well as it is not wide enough so the first couple of layers are added here to give me something to lay up against when I start to widen it properly.
While that was curing I blocked down the filler on the roof and then fine sanded it ready for paint. With that done it seemed finished so I cleaned it all down and laid a coat of primer over the area.
All looks good so far, I'll do a proper inspection tomorrow but I think that bit may be ticked off the list now.
Roof looks good today, laying a straight edge along it I think there may be a couple of low spots still, so some more work needed to get it perfect.
Roof panel fits far better now though;
Getting back to the rear wings, I cut some aluminium strips and bent them to match the wing curvature. Then some drill holes and some Cleco's and thay are fitted in the correct place.
Then some glass was added on the inside to bridge the gap which will hold the parts in the correct place for working on them properly.
While that was curing I started a job that has been on the waiting list for a while. The drivers door when it was repaired ended up hitting the door frame when it closed. A nice big slice down the inner door frame and a lump of metal in the gap when the door was closed moved it to the correct gap. It just needs welding back up again now.
I know I said the bulkhead was finished........um.........seems it wasn't
Front wing is getting cleaned up ready for some surgery as well.
Another session on the car today. Phil came over to help as well so his first job was removing the rest of the caulking under the car & cleaning it all down with degreaser - I save all the best jobs for him
The wings were ground down ready for the new glass layers to be put back in.
and a bit later they had the first 4 layers of mat bonded on;
Front wings were sanded back to glass all over the inside and the headlamp recesses were deleted;
As were the indicator holes and also the holes for the wing stays. The indicators will be moved nearer the outside of the car - partly to comply with the law but mainly as a safety feature as no-one looks at the centre of a car for indicators. These will be ground back like the rear wings before new glass is added to the front.
Meanwhile Phil was tasked with rubbing down the inside of the front grillshell. After he cleaned to shell we were amazed at the quality of the original paint, not bad for over 60 years old!
and some time later it's mostly done. I'll go over a few of the rusty areas a little more before rust treatment, then it will be ready for primer.
Phl had to leave a little earler today but I carried on a bit longer. I started by making a template that fits the filler neck properly using CAD
which ended up like this - the hatched area shows the hole in the car which is over size and needs to be filled in.
I forgot to post a couple of photos from last night, rear quarters had a last skim of filler yesterday to fill the known imperfections;
But to keep it in time order we go back to the filler neck hole. Carefully tacked the extra plate on the inside as there is enough room in the rubber seal to accomodate 2 thicknesses of steel.
this was then sanded back as was yesterdays filler to the stage where some primer can be applied to highlight all the bits I've missed
This has revealed a few areas that need a bit more work plus a couple of areas I had not spotted before, it's all final tiny skims now though so this will be another area soon to be ticked off the list. Pretty pleased with it so far.
Looking good. Are there arches made that fit properly, or are all the aftermarket ones (assuming there's more than one supplier) wiblepoo? I love the level of detail going into this, those small tricks to put in the old grey matter for future projects!
Arches are quite good quality - these came from Pro Laminates but the mould could do with a bit of tweaking. All Pops are slightly different shapes - it was not high tech production lines in those days!! but there is certainly room to improve them.