Bodywork 4
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This is the page where I will document the work done on the body parts after the molding.

All references to pictures are to those above the relevant text.

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Working on the body

050205withhood.jpg (94235 bytes)  050205satinside.jpg (116809 bytes)  050205satinside2.jpg (63126 bytes)

Picture 1 is the roughly trimmed body with previous hood (bonnet) in place. The picture has been doctored slightly to show an enlarged cockpit area. Pictures 2 and 3 show the need for more elbow room (not as much a problem on a seven)

9-5-05-rearbody.jpg (105483 bytes)  9-5-05-rearbody2.jpg (94222 bytes)  9-5-05-rearbody-underside.jpg (77638 bytes)

These pictures show the amount of space available for chassis widening. Will I do it now?..... I don't know, time will tell I guess. It may be a change for mk.2.

070405-bodymounts01.jpg (100730 bytes)  070405-bodymounts02.jpg (120360 bytes)

I decided it was about time I mounted the body in it's correct location. Obviously this is logical step forward in many ways, least obvious is the fact of just how much stiffer it feels. That should make the body paint prep a lot easier. It turned out the front mounts each needed 4.375" extensions and the rears 2.25". I may do some bracing back to the frame and between the mounts for a little extra side impact protection, again, we'll see.

9-5-05-front-corner.jpg (84240 bytes)  9-5-05-front-temp-grille.jpg (97067 bytes)  9-5-05-rad-under-hood.jpg (90900 bytes)  9-5-05-rad-underneath.jpg (102322 bytes)

9-5-05-under-arch.jpg (93272 bytes)  9-5-05-under-arch-with-rad.jpg (106267 bytes)  9-5-05-fitting-rear.jpg (58619 bytes)  9-5-05-mounting-rear.jpg (75519 bytes)

Pictures 1 and 2 show the front cut out and a temporary grille in place (it's a piece of wire mesh sprayed black). Pictures 3 and 4 show the radiator and how it fits with the bodywork. Pictures 5 and 6 are more views under the front wheel arches (fenders),. Pictures 7 and 8 show the beginning of preparation of the rear end. Not shown yet are the hinges which I made ages ago which hope to be able to still use. link

100905-hinges.jpg (36687 bytes)  100905-inside-rear.jpg (53825 bytes)  100905-headlight-planning.jpg (58042 bytes)  100905-headlight-planning02.jpg (109368 bytes)

100905-light.jpg (43533 bytes)

Two different areas of work here. Pics. 1 shows the hinge mount bracket that will be "epoxied" into the rear end pic 2. Pics 3,4 and 5 show the challenge I face deciding what to do with the headlights. The lack of horizontal space along the line of legal height (the heavy line tangential to the top of the wheel opening) is the problem. Sure, they will fit, but clearance at the upper wheel travel will be minimal/non-existent. Previous work and ideas are here.

102305hinges.jpg (63793 bytes)  102305hinge-mounted.jpg (69890 bytes)  102305rear-end.jpg (61454 bytes)  102305rear-flipped.jpg (119161 bytes)

102305front-hole.jpg (68826 bytes) 102305front-hole-filled.jpg (71050 bytes)  102305front-hole-side.jpg (89868 bytes)  102305front-hole-side-filled.jpg (75080 bytes)

Pics. 1 and 2 show the hinges mounted, pics 3 and 4 are fairly self-explanatory, with 4 showing the cutouts for grills. Pics 5 and 6 show a front view of the air scoop I'm going to do on the front, 5 is real and 6 is "artists impression" of what it will be like. Similarly, pics 7 and 8 show real and planned views from the side. 

12-18-05-Scoop1.jpg (96132 bytes)  12-18-05-Scoop2.jpg (117393 bytes)  12-18-05-Scoop3.jpg (41628 bytes)  12-18-05-Scoop4.jpg (67662 bytes)

Four pictures of the air scoop plug (for want of a better description) underway. Pic. 1 shows how the finished molding will sit, pic. 2 shows the hood placed on it, but sitting up a bit because the scoop plug is oversized. Pic. 3 shows the start of the clay process, and pic. 4 shows the PVA release agent sprayed on. Notice how I put a clamp on the lower piece to force it to be convex, otherwise it was tending to bend the other way.

Meanwhile......

12-28-05-better-wheels.jpg (95614 bytes)  12-28-05-better-wheels-rear.jpg (121468 bytes)  12-28-05-rear-wheel.jpg (58231 bytes)  12-28-05-transparent.jpg (127914 bytes)

Ok, the mold is made and PVA'd ready for gel. Meanwhile I temporarily placed my Focus wheels on the car. Oh yeah, and I did the transparent trick in picture 4.

Back to the scoop

011206-gel.jpg (76758 bytes)  011206-mold.jpg (96121 bytes)  011706-scoop-fitted.jpg (83237 bytes)  011706-scoop-fitted2.jpg (69300 bytes)

011706-scoop-fitted3.jpg (82402 bytes)  011706-lights-concept.jpg (49093 bytes)

Pic. 1 shows the gel on the mold, and pic. 2 shows the layed-up mold. Pic. 3 shows the finished part after trimming and fitted in place, and pic. 4 shows the hood down n the scoop. Pic. 5 shows the clearance between the scoop and suspension. Pic. 6 is my idea for the lights (yes, another idea) it shows the small rectangular lights set inboard (at legal height),  but still gives the chance to use the Hellas mounted low in the fenders (front wings) as extra driving lights. 

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