Flares....

[911hillclimber]

IIRC, (which is not often) the RSR shells were modified off-line by the factory, and the hand made arches gas welded to the existing wings, and, as race cars, the irregularities were readily accepted from one car to another.

The front wing profile is not a true radius but has a slant to it behind the apex of the arch towards the A post.
In Darren's picture gallery, the 2 white cars show this form identically so were the original flare pressed or indeed hand rolled?
With the white race version the front wing flares are quite different.

Pointless leaving the shell in 'no-paint' as you will NEVER see the welds Barry has performed....

[Darren65]

Arrow straight and on the jig .....



.....Barry has sent me a few updates now as he's worked through a number of repairs

I'll post details soon.

Cheers,

[Gary71]

Bring on the metal working pics

[Bootsy]

Good good

[911hillclimber]

Obviously going to be a 10 minute job.
Hope Barry will show all soon.
Great start, far better than most.

[inaglasshouse]

That does look refreshingly free of surprises, Darren. Lovely!

[yoda]

What a super starting point - great shell even before the work has begun!

[Darren65]

Thank you chaps....I have been lucky with this one and the shell is refreshingly straight and solid....

....although, as always, a little saggy at the tail end....



...easily sorted with a couple of jacks...



.....

[Darren65]

....and of course there is (was) a degree of rust....











[









....

[Darren65]

....and here I have to confess that I've become a little blasé .....I don't under estimate the skill involved, or the precision of which Barry carries out his tasks.....but the man just does it so effortlessly and seamlessly that he makes it all look so easy! .....































.....

[inaglasshouse]

....and here I have to confess that I've become a little blasé .....I don't under estimate the skill involved, or the precision of which Barry carries out his tasks.....but the man just does it so effortlessly and seamlessly that he makes it all look so easy! .....
.....

Maybe we could persuade Barry to make a total balls-up of one car (not yours, of course), to reintroduce a sense of jeopardy to the narrative.
Looking good there Darren, and looking forward to seeing how this one takes shape.

[Darren65]

....the sills were in great shape and we even contemplated keeping the original outer sills with a few fixes although we decided to remover these to reveal perfect inner seals that required fairly straightforward repairs...

















....

[Darren65]

....Maybe we could persuade Barry to make a total balls-up of one car (not yours, of course), to reintroduce a sense of jeopardy to the narrative......

....now that would be novel although I can't see it happening anytime soon!

...there's a few gems with Barry's updates and I particularly enjoyed this email.......in Barry's words .....

'This is where the time goes! There was a bend in the top of the door skin, I guess where the frame had got bent over at some point.

Although it was right in front of me, I simply couldn’t get a direct pull on it to straighten it, either from top or bottom. The bit of bent steel is the thing I usually use to pull out distortions in the rear slam panel lip (on the engine side). The little end goes under the lip and I can tap the large end.

In this case, I welded a washer onto the little end so the whole formed a hook. I could then get that under the edge of the bent flange and lever it straight via the top edge. A quick weld to kill the stress crack, remove washer from the tool and clean it up and onto the next bit. It’s the little things that take the time.

The rest was template, fabricate, mark out, first cut and remove, second marking, cut and remove, fettle, de-rust, key up, prime, tack, tweak, weld / cool / weld / cool (etc), linish, file, tap up, sand, gap, photograph. Time for tea!'











....

[911hillclimber]

He is brilliant as ever.
Wings on very soon.

[Darren65]

.....as much as I'm enjoying seeing the shell becoming a perfect form....and I'll always maintain that a Barry Carter restored shell is the best value money you'll ever spend on a restoration ....what I'm getting really excited about is seeing the modifications to transform this car into a 3.0RS.

One of those items will be the modification of the pedal box area.....I visited Ben Coles this week to pick up a new pedal box and the sheet metal to allow the fitment of twin brake cylinders and an adjustable bias.....only problem being is that he only makes them for LHD cars as this....



....although I do have a few reference photos from #9092....



....pedal box as seen here looks to be slightly different to LHD ones.....



.....I'm not sure what Barry (and Gary Cook) will make of Ben's wonderful pedal box kit although no doubt it'll need a fair degree of work and fettling to transform it from a LHD to RHD form....



.....but then with only six of these cars ever built for our side of the road I dare say this is exactly what would have happened in period!

Cheers,