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Well I managed to get a couple more panels finished for the rear of my scratch build, and it's starting to look like something. Now I think I'm getting the hang of this stuff and just to show how and what you have to do sometime.
The mold http://www.ffcobra.com/photopost/dat...010_Small_.JPG The business side is covered with the wounder material ductape. The layup http://www.ffcobra.com/photopost/dat...014_Small_.JPG Now prying this off the mold was a PITA but it's a weird shape. Trimmed and refit http://www.ffcobra.com/photopost/dat...016_Small_.JPG It fit back easier after trimming With friends http://www.ffcobra.com/photopost/dat...015_Small_.JPG Now it looks like progress. I think I will work on the trunk next, until later see ya. Patrick |
Hey, check out my new duct tape trunk!
http://www.clubcobra.com/photopost/d...022_Small_.JPG Naw, It's just the next mold for my glass Odyssey. http://www.clubcobra.com/photopost/d...018_Small_.JPG http://www.clubcobra.com/photopost/d...017_Small_.JPG Now with a little luck I'll has pieces by Sun. eve; Patrick |
Largest layup to date, today I successfully laid up the trunk for my car and now the shop has to vacated for a while to vent fumes. About 1.5gal of resin and a s*#t-load of mat later this is what I have.
http://www.clubcobra.com/photopost/d...023_Small_.JPG http://www.clubcobra.com/photopost/d...024_Small_.JPG http://www.clubcobra.com/photopost/d...026_Small_.JPG Patrick |
Hey, everything worked well and I now have a trunk. pieces all trimmed and refit. now I knew I would have to cut it in half to get it to work but I will fasten them together during final assembly.
http://www.clubcobra.com/photopost/d...029_Small_.JPG http://www.clubcobra.com/photopost/d...030_Small_.JPG http://www.clubcobra.com/photopost/d...032_Small_.JPG http://www.clubcobra.com/photopost/d...033_Small_.JPG Now to move forward. rear cockpit wall, tunnel, and custom dash are left. Lurkers, I know this thread gets lots of traffic, so speak up good or bad I would love to have your opinions. Plus I don't get out to much so this is as close to contact as I get sometimes. Patrick |
Well one more panel done. Rear cockpit firewall,
http://www.clubcobra.com/photopost/d...036_Small_.JPG http://www.clubcobra.com/photopost/d...039_Small_.JPG http://www.clubcobra.com/photopost/d...038_Small_.JPG Now I have some artistic carving to do, the tunnel and dash are next this is where things are going to slow down a bit. Patrick |
You caught me, I was lurking, so now I'll speak up... How did you get the long radius? I saw the tubing bender in the background, but no roller. BTW, what brand is that bender and where did you get it?
Great work, can't wait to see it finished and some vids! Micah |
Hey guys,
I've been busy lately trying out some new things. just a peek at what will be the dash / tunnel cover for the scratch build. now I could never have a stock dash in this car. So as per usual I'm going overboard with a one piece unit that will house all the gauges, switches and whatnot. It is still in it's crude form(lots of sanding required), then I can pull a mold of it to make the final part. I'm still on the fence if I should cover it or paint it to match the car. http://www.clubcobra.com/photopost/d...043_Small_.JPG http://www.clubcobra.com/photopost/d...042_Small_.JPG Patrick |
After a bunch of sanding I am close to final on the dash plug some small holes to fill and edges to finish and I should be able to paint and start waxing the f___ out of it. I just hope that the body isn't this hard to work on.
http://www.clubcobra.com/photopost/d...045_Small_.JPG http://www.clubcobra.com/photopost/d...044_Small_.JPG The rings are for the gauge placement, shifter location, and sanding guides the incomplete ring is where the column goes. Patrick |
Alright I'm only typing this reply once and posting it around, so here's the answers.
Never even thought about the womanly shape, weird. Yes the large gauges are angled slightly toward the driver. Not really a big fan of the carbon fiber look, would love to stretch some fine leather over it. but will probably just cover with something to coordinate with the seats when the are redone. The mold will be three pieces and will have to be done in the car. The plug is built up on the chassis so it will be destroyed after I have molded one from the molds( when I have made the final piece I would like to see if it would fit other cobras as well). Here's a pic with the fake gauges and seats in the car there is not a lot of space for access so the seats will pop out and the whole piece will lift out and unplug for maintenance. http://www.clubcobra.com/photopost/d...048_Small_.JPG Patrick |
Well, I don't know if it will be worth the effort I put in to it, but I have finally finished that crazy dash of mine. lets see eight weeks, 2 gal. of bondo, six cans of foam, countless hours of sanding, about 1.5 gal of resin, Oh and let's not forget two surgeries and a short hospital stay. but it is done for now, and it fits. Laid up two layers of glass over the plug and pulled it off and the laid three layers from the underside then trimmed.
http://www.clubcobra.com/photopost/d...063_Small_.JPG http://www.clubcobra.com/photopost/d...064_Small_.JPG http://www.clubcobra.com/photopost/d...065_Small_.JPG http://www.clubcobra.com/photopost/d...066_Small_.JPG Well, off to work on something else. Hey any Ideas on what to use to bond the hood, trunk, and doors to the metal frames. I'm thinking that goo they use to bond car panels together what is it called. Patrick |
Hey just for a laugh I was messing around with an Item that followed me home from the latest "5-S" event at work. I was thinking of polishing it and and useing it as a pistol grip shift lever:cool:
http://www.clubcobra.com/photopost/d...070_Small_.JPG http://www.clubcobra.com/photopost/d...071_Small_.JPG It has room for four buttons, I figure one for the dimmer switch, two for spray (arm and blast), but what about the fourth? Patrick |
After spending all that time making panels for my car I didn't want to simply rivet them to the tubing. Not my style plus I didn't want all those holes in my chassis. So I spent an immense am out of time making little 1"x1" tabs with threaded holes to fix the panels to with screws. I haven't put the panels back on yet, but the tabs were tacked in place screwed to the panels so they do still fit,
http://www.clubcobra.com/photopost/d...075_Small_.JPG there are over fifty of them welded to the back half of the chassis. I can't wait to do the rest of the chassis at least that will all be metal. Patrick |
Have been in a slump lately and could use some encouragement that everything will workout just fine. Put the body back on the frame and wouldn't you know the door frames wouldn't fit. So after cutting out the door jams that I had done last fall I made molds in the car and glassed up some new ones.
http://www.clubcobra.com/photopost/d...081_Small_.JPG http://www.clubcobra.com/photopost/d...078_Small_.JPG Then back to the doors now with new jams the door frames had to be adjusted to fit again (just modified the pin catches for more clearance). Finally after getting the door frames to work smoothly again, I could make some tabs for glassing the door skins to. Now to get up the nerve to start fixing the skins to the frames. http://www.clubcobra.com/photopost/d...082_Small_.JPG http://www.clubcobra.com/photopost/d...080_Small_.JPG Man this is taking way longer than I thought; Patrick |
Well it's been almost a month between posts without a whole lot of progress.
My guy at the auto body supply store recommended a urethane window adhesive. Said something about flexibility for differences in expansion rates. Now as far as what to glue into place is what has been taking the most time, after one failed attempt I had to go with plan B. Don't ask for train wreck pics they do not exist, but I will not work with foam ever again. I did manage to get the inner door panels made and the glue is setting as I type. http://www.clubcobra.com/photopost/d...083_Small_.JPG http://www.clubcobra.com/photopost/d...084_Small_.JPG So tomorrow I hope to glass the seams and put these doors to bed. The skins were glued and glassed to the frames, I also coated the frames with POR15 because I will never get a chance to do anything to it again. http://www.clubcobra.com/photopost/d...087_Small_.JPG Give me a couple of days and I may get these done and refitted to the car and I will update you then. Patrick |
Da-am was that fun NOT, but hey they are done! Now I can't tell you how much filler and sanding these will take to finish but I have a base.
So here is the pics of the doors in full rough. http://www.clubcobra.com/photopost/d...090_Small_.JPG http://www.clubcobra.com/photopost/d...093_Small_.JPG http://www.clubcobra.com/photopost/d...094_Small_.JPG http://www.clubcobra.com/photopost/d...095_Small_.JPG Now it's up to all of you lurkers to post up a comment; Patrick |
Well I've done it I have finished the major fiberglass fabrication of my build, panels done, dash done, doors done, hood and trunk done!
http://www.clubcobra.com/photopost/d...101_Small_.JPG http://www.clubcobra.com/photopost/d...102_Small_.JPG I have quite the inventory of items created with fiberglass for someone who had little expeirance with this stuff I think I did pretty good. http://www.clubcobra.com/photopost/d...103_Small_.JPG http://www.clubcobra.com/photopost/d...104_Small_.JPG The body is tucked away back on the ceiling, I hope not to see it down till bodywork part of this project. I have a couple of loose ends to clean up on the chassis and it's off to powdercoat then I may get to start putting this thing together for real. Patrick |
Well what I thought was going to be easy wasn't. Had to move the shifter forward about 5 inches, no problem just make a Z-bend shifter, YUK that sucked the movement was all wrong, how does someone ever get used to that. I couldn't so I did what I always do Go overboard and build some over engineered contraption to do the same job. With a bunch of junkyard parts and a fair amount of time I came up with this.
http://www.clubcobra.com/photopost/d...106_Small_.JPG http://www.clubcobra.com/photopost/d...113_Small_.JPG http://www.clubcobra.com/photopost/d...114_Small_.JPG http://www.clubcobra.com/photopost/d...118_Small_.JPG Pictures submitted for approval, some days I think I should be committed; Patrick |
It's finally back from powder coat, the guy's at Extreme Powdercoating(www.extremepowdercoating.net) came through, other than being delayed by a very large job. Greg and Todd were very helpful and truly interested in doing a great job. Now here are the pics.
http://www.clubcobra.com/photopost/d...126_Small_.JPG http://www.clubcobra.com/photopost/d...123_Small_.JPG http://www.clubcobra.com/photopost/d...132_Small_.JPG http://www.clubcobra.com/photopost/d...127_Small_.JPG Well I guess I will have to start putting this thing together. Starting with aluminum for the floors and firewall, I'm thinking .050 should be thick enough for the job. Patrick |
Hey just a quick update, I have started making aluminum panels for the car. Went out and got some .063 6061 sheet and went at it. Have made small steps so far. Here are my foot wells they were a lot more work than you would think.
http://www.clubcobra.com/photopost/d...135_Small_.JPG http://www.clubcobra.com/photopost/d...134_Small_.JPG that's it for now, Patrick P.S. where did all my friends go? |
Hey, I have created a couple more pieces of aluminum this week. We now have floors. How do the look to you? I feel everybody has deserted me. There is hardly any traffic on the forum:(, so reply if you can. (that means all you lurkers out there)
http://www.clubcobra.com/photopost/d...136_Small_.JPG http://www.clubcobra.com/photopost/d...139_Small_.JPG I'll keep working on it but I like the feedback. Patrick |
Well, it's been two weeks so I figure I better post some thing, to stave off loss of interest. I finally finished the backbone sheet metal. That has to have been the worst thing I have ever had to cover in my life. So sorry if this does not hold up to all of your high standards of my work. I plan to cover all the aluminum with either textured coating on both sides or paint / textured where you will see the aluminum. To me it looks like it was beaten into submission.
http://www.clubcobra.com/photopost/d...144_Small_.JPG http://www.clubcobra.com/photopost/d...143_Small_.JPG http://www.clubcobra.com/photopost/d...146_Small_.JPG http://www.clubcobra.com/photopost/d...148_Small_.JPG I would personally like to thank everyone who replies to this thread you really do keep me going, because this isn't as easy for me as you all think. Patrick |
There now you all have the whole story, start date 11/04/05 the last post was made one week ago.
I moved the story over here because the original forum has been losing interest in my project and I need some new blood and opinions injected to help fuel my work. This is nowhere near an easy project and many times felt like passing it on. But kind remarks and support from others have kept me going to the finish. I'm nowhere near done and have a lot of work ahead of me, so come along and speak up and I will continue to update this thread until I'm done. Patrick Oh, I do have a roll bender I built it my self. http://www.clubcobra.com/photopost/d...762_Small_.JPG No money for aluminum body how about lexan. |
Keep at it, you sure have come a looooooong ways!!
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woooah.. awesome build.. and super pictures and buildlog... but making the move here can be expensive... you will get crazy forced induction, wheel/tire ideas in no time....
love the shifter by the way, sturdy and well thought out idea, think ill copy it for my 65 mustang if you dont mind? |
Holy Crap!!! This is an awesome topic, and I really enjoyed seeing it come together... I don't get on the forum too often anymore, so I think this is the first I've seen it. :thumbsup:
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Nice work! Love the glass stuff.
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Very nice build. And congrats on doing all the work yourself.:cheers: keep us posted
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Great project and great work you do
but its going to get lost and get no real credit as a fiberglass car. fiberglass cars are everywhere to get real attn it needs to be aluminum. my opinion. |
sell the minivan and buy an aluminum body... :)
the wife and kids will get over it in time :) |
An aluminum body for one of these is north of 20 grand I don't have that in the whole project to date. Now if someone were to come out with a clear lexan one complete with doors, trunk and hood, to show off all the work underneath it I'm there. Only way for me to get aluminum is to pound one out myself.
Patrick |
nosense... unless you wanted to polish it there is no need for aluminum... i am not in total agreement on the engine choice... i think there is more bang for the buck in a chevy LS engine.... but for gods sake dont change a thing... doing so in mid build always costs money
its plain awesome... so post moer pics please.. also didi you go by some plans for the frame, or just a picture and the seat of your pants?? |
Holy WOW Batman! That thing is simply amazing!!!!!!
Shiny Side Up! Bill |
Dude, you have riteous skills. Just amazing.
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WOW WOW WOW
Nice Work. I like how you posted all of your update for us to bring us up to speed |
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I live in the southeast metro, twin cities Minnesota. I work for a supplier to truck equipment dealers. Yes it is a joystick from one of our plow truck controllers. Our 5s has been winding down for a while now, but it was worth it our facility got the green light to skip physical inventory for the first time in company history. Anyone local is welcome to stop by the garage,:cheers: and check it out in person.
Patrick |
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Same here, I'm in Southern MN and work for McNeilus Co. It almost looked like one of our joysticks out of our cement mixers. Boy it sure would be nice to skip inventory here, haven't done that for years.
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More beaten aluminum
Well I've gotten a few of the panels for the firewall pounded out (literally) so here are the obligatory pictures. I have all the pieces cut out for the rest but I'm fitting them up and trimming to fit as I go. When I get them all fitted I will go back and do the final trimming and cleanup. Then I will coat them with some sort of textured coating and get them riveted in place.
http://www.clubcobra.com/photopost/d...154_Small_.JPG http://www.clubcobra.com/photopost/d...155_Small_.JPG http://www.clubcobra.com/photopost/d...156_Small_.JPG http://www.clubcobra.com/photopost/d...157_Small_.JPG Oh, by the way here is proof that I must hate myself, the top of the foot box is made from one piece of metal Aluminum origami. Patrick |
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