1987 3.2 Carrera Backdate project - Sladeys hotrod

[sladey]

Cheers mate thanks a lot

[sladey]

Whatever - I've got to finish my shed before I can get back to the panel beating and welding
Mark

Well that's done then (http://www.ddk-online.com/phpBB2/viewto ... &start=105)

So I'm back onto the task I stopped about a year ago.

a couple of weeks ago I had to repair my exhaust back-box and I tried the pulse/spot welding technique - worked an absolute treat, was much more controllable and produced a nice series of welds.

So I finally returned to the wing I've been working on.


this bit needs some attention. There's a rust hole at the bottom, part of the supporting flange has gone a bit lacey, and there is also a previous repair there.
There are 2 bits that need making - the dimpled supporting strut thing you can see (with the two holes in it) and also the metal it sits on - that's got the rust hole in it. There's a gap behind it so crud will have got in there and rotted it a bit.

[sladey]

So out with the cornflakes packet and after a bit of beating and shaping I'd got this



Then I wanted to make the dimple/pressing in the middle to give it a bit more strength, so I started out with a hole


And a bit of beating later I got to this


and then this


Thinking about it later it would have been better to produce a 'male' buck instead of a female one - might have lead to fewer marks in the metal. One to remember for next time.

[sladey]

I was quite happy with this initially


But then I looked round the back I knew it was going too well


You can't see it wonderfully well in the pic but there is a flange that curls under from the metal underneath and my new dimple was getting in the way!

Time to bring in the persuader

First I chopped off part of my jig


then after a bit more persuasion I created enough space for the flange


Here it is held in place

[sladey]

Next to start on the bit of metal underneath - I first hammered a flange over and then started to put kinks into it to create the necessary curve


After a lot more kinking, heat shrinking and beating I ended up with this:-


So the two pieces will fit together like this:-


This week-end I'm hoping to do a bit of cutting and welding.

[Darren65]

Great job - a Barry Carter in the making!

[964RS]

.........so I started out with a hole

That's where all the problems start......

[jury]

Great stuff Mark, very impressive...!

All finished for July ?

[sladey]

Dunno about that - might have one wing on in primer - maybe paint - we'll see

[jury]

Love the primer look

[sladey]

Good week-end's work:-

Cut out the rusty (er) bits



Weld in the bottom bit


And the top bit


Wih the support done, time to make the outer skin (this is my third attempt - previous ones either didn't get the shape or had too many hammer marks)


Just resting in place


Tacked:-


First few welds


Done


And smoothed off:-


I was really happy with this. I tapped down a high spot and caused a minute crack in one of the welds - still learning, but enjoying the process. The pulse-style welding is really working for me - I can see where the next weld is to go - whereas when I try and lay a bead I sometimes go off-line and don't know what to do if it goes wrong. The pulse welding just works and looks neat

[jtparr]

Top man
Well done

[sladey]

Thanks Jonathan,

I'm enjoying the journey for it's own sake, and each mistake is a new lesson. However the latest job started to feel like progress was being made and I might actually put this wing on the car one day.

[jtparr]

Yup, agree making progress is a necessary part, gives you a bit of a boost, look forward to seeing more !

[bjmullan]

Fantastic work Mark