764 replies to this topic

[Deathrow]

Just wow!

I love watching your fabrication work. This car is going to be so awesome when it's done.

[skyblueads]

Looking good mate, have you got a target for when it's likely to be on the road?

[panelbeaterpeter]

Just read the whole thread, nice work. Loving the centre console, beats MDF any day!

[Mini-Mad-Craig]

Amazing

[Tupers]

Thanks for the kind words guys, I'm aiming to have it done in time for next years show season although I'm not putting an exact date on it as I don't want to force it.


I got the dash rail bolted in and decided to weld it up while it was completely ridged.


After playing with the dials yesterday I realized it would be easier to build the top if I cut the original section off.


I cut it down to this and also cut off the two spikes as I only eyeballed them so the weren't really in the right place.



The next job was to cut the bottom lip off the dash rail as it now caught on the original rail bellow it.




And I did the same on the opposite side.





Having made more room above the dials I welded them back in and mocked up the curves above them in card.




Once I was happy with the shape I made them in steel, they still need tweaking but they're getting there.





I also bought some shinny new tools, I'm going to need a bigger tool box soon.

[mk1leg]

That will be one stunning clubman estate when finished ........so keep up the good work and more pics.............

[Tupers]

That will be one stunning clubman estate when finished ........so keep up the good work and more pics.............

Thanks fella stunning's what I'm going for. How's this for more pics, 9 for one piece.


Last week I barely did any work on the estate as I was busy with my other job but as of this morning I'm back in the work shop and decided to sort out my tank box.

I started out by trimming the back lip of the box to fit the cut out in the floor.


Pulled it over to the bench to finish the cut and flap wheel it.


Popped it back in to check the fit.


The lips coming of the ends where to long so they where the next to get the chop.


After a bit of cutting.


And the front lip saw also oversized so that got chopped as well.


Cut down, I also radiused the edges as I thought having sharp edges as around chest height on the bench was a bit sketchy. :whistle:


I sat the box in again to see how it looked. I should be able to fit another box in under the seats big enough to house two batteries and something special.


Last of all I popped a load of holes in it and hopefully I should have it all welded in the end of the day tomorrow.

[skyblueads]

I popped down to Mintec last week and saw the car, had a chat with your Brother. Car looks really good, the work is really impressive. Really enjoying this thread!

[Tupers]

I popped down to Mintec last week and saw the car, had a chat with your Brother. Car looks really good, the work is really impressive. Really enjoying this thread!

Thanks Adam I'm gutted I didn't get to see you, glad you like it though.

Yesterday I had Dad welded up the seams in the tank box from the inside and then I took the welds on the out side down with a flap disc.


It took a while but you can barely tell it's not one piece now.


I painted the hard to get at bits with a couple coats of red oxide.


Dad welded the box in yesterday while I was out.




I made up a plate to go in each corner at the back as the box didn't cover these areas.




He wasn't able to weld right to the end as the floor curves down so I cut a slit behind the box, clamped up the lip and welded the rest of it up.




My new Smith & Arrow 40 grit flap wheels turned up today so I though I'd take down the plug and seam welds. There'll be a false floor over this but it's nice for it to look as good underneath as it does on top.



I wont be using standard rear door so I got with of the top and bottom bolt receivers.
The bottom was easy as I only needed to cut out the old area, weld in a flat plate and flap wheel it down.






The top was a real pain as all the work was about my head but got it cut out quite cleanly.




The door frame is actually double skinned so I welded in the top section first.


Then I made a new outer section and welded it in, there's nothing like blobs of mig falling onto your crouch to scare you.







More tomorrow.

Edited by Tupers, 22 September 2010 - 08:12 PM.

[Deathrow]

...there's nothing like blobs of mig falling onto your crouch to scare you.

Amen to that!

Lovely work! Really interested to see how that dash comes out.

[skyblueads]

Thanks Adam I'm gutted I didn't get to see you, glad you like it though.

I thought it a good idea to at least pop down and say hello, you guys have got some cracking cars down there. Glad to see FOM is progressing nicely.

[Tupers]

So it's eight days late be here are some more pics.

I took the welds on the door frame down with a flap disc. It was almost as fun as welding it in but it does look good.




I decided it was about time I sorted out the space in front of the tank box so cut out some steel.


Dad gave me a hand and we rolled a few swages into it to stiffen it up.


I then put it in the brake and folded it up.




And after a bit of trimming to the floor I slotted in in front of the tank box.


The swages even line up.


Hopefully the next update wont take so long.

[panelbeaterpeter]

Looking great dude

[DaveJH]

Wow, left your thread for a week or so and boy have you done some hard work in that time! Looks great, those swage lines make it look like a genuine part. Well done!

[Tupers]

Thanks guys, the battery box has been coming along a lot smoother than I thought it would. I should have it all welded in by monday lunch time and I can move onto finishing the centre console, dash and maybe make a start on the rear seats.


I made the sides for the battery box up this afternoon and put a nice swaged line in to match the other sides and base. The top of the these and angled to match the drop in floor height from back to front in the estate.


I clamped the box down to our steel bench take out the curve in the base and test fitted the right hand side.


Put a few tac welds on each side to hold it in place. Tomorrow I'll get dad to seam weld it inside and out, I could have done it but he's better at it than I am.


Here it is with both sides on, I do love it when a plan come together.