Part 6 - Front and Rear Bodywork
Here we are starting a major part of the car: the aluminium panels. Its
very important to get these absolutely perfect; as these panels form the
major part of the exterior of the car. Any nasty creases, bends or bumps,
and it could spoil the look of the car.
This is the first panel to be fitted; the rear panel which covers the petrol
tank area.
First of all, the card template is transferred to the aluminium sheeting
and the aluminium is cut out.
The sheet is then fastened to the chassis with G-clamps and soft wood, so
as not to mark the metal. It is easier if the bottom is bent round and fastened
before any work is carried out on the top.
The sides of the aluminium sheet are carefully bent around the corners of the chassis and are bent over the a chassis member and rivetted on the inside of the chassis so they cannot be seen.
The top is a little harder in that there are two radius-es that need to be dealt with. It is best to take your time and go slowly with this; dont try and bend the entire corner section over at once... you'll get creases, go slowly and work your way round a little at a time and it should come out nice and smooth. A fine file and emery paper can take out any imperfections caused by the hammer on the top chassis rail.
With the rear section in place, it is now starting to look a bit more like
a proper car!
The next main panels toget on with are the side panels.
These panels run the length of the car, from the front edge of the rear
wheels, to the back edge of the nosecone. As mentioned previously, there
are two main methods for this; a single section of aluminum which looks
very neat, but requires the cut-outs for the suspens to be perfect, and
a two piece method which is joined below the scuttle.
We decided that a combination of the two ideas would be best.
We will make the side panels in two pieces, but instead of joinging them
half way along the car, we will have a very short panel which will just
cover the suspension and steering area joined to a single panel which runs
the remainder of the length of the side. The join will not be as noticeable,
as it will be hidden by the wishbones, tyres and the front cycle wings.
This also has the advantage that this single piece can be changed if damaged
by the suspension, for example.
Both side panels and the panels for the suspension area have been made and are now both fixed in place with G-clamps. We have decided NOT to afix these panels permanently at the moment; we still have the exhaust manifold to finalise, the pedals to setup (springs etc.) and the engine to finish.
Next: Finish rebuilding the engine and fix the side panels in place.
This page updated: 25/Mar/2007