One Wheel On My Wagon... Part 1

Well hello again bloggers!

It's been too long, way overdue for a proper update. So here it comes, excitingly split into two parts for your reading pleasure.

As mentioned recently, my big order was completed (save for a few items) so eagerly I agreed to meet GKD just outside Stonehenge. I managed to convince my (now) wife to come along, with the proviso we'd do the touristy thing at the ancient monument on the way back. So that's what we did!!

How to fit a sportscar inside your Discovery

After I got home I unpacked and checked everything and organised and distributed it around the workshop

Next day I was straight up to the workshop to press on with the build. First up, aluminium panels - which was RIVETING (boom boom). Although, couldn't resist the urge to trial fit as many pieces as I could to get the vision of success!!

 I begun by building up the panels around the transmission tunnel and the back of the cockpit. I then discovered perhaps for the first time, and maybe not the last time, a disadvantage of building out of sequence - couldn't fit the driver's side front transmission tunnel panel the "proper" way, on account of the gearbox being in the way. So I had to trim and adapt it, and use nuts and bolts to secure it at the bottom instead of pop rivets. But, if that's the worst that happens I can live with that.

 rear panel was next - Measured the middle, riveted the flat panel in place, and then carefully  bent it around and riveted the ends. Incidentally, decided not to go to the expense of cleko fasteners and just using a pop rivet in each corner, which I will later drill out. No real extra effort, and I guess a few rivet heads will be forever lost inside the chassis, but I'm sure I won't be able to hear them scream over the glorious noise of that lovely exhaust.

 I then proceeded to pein over the lip on the top, and I genuinely surprised myself at how well it turned out. Might need a bit of trimming to make it look A1 neat, but I plan to have a tonneau cover eventually, so won't be on show all the time.

Then, first problem - Rear cockpit panels didn't match, I later discovered the side panel was also too long - after a few emails with Peter I discovered that the new chassis is 50mm longer than mine, and thus the panels are altered to suit. Not a problem as such, just need to trim and bend to make fit - it's 2mm aluminium so it can be worked quite easily. Rear cockpit panels received a couple of deft blows from a rubber mallet, and the side panels I marked up with a straight edge and will cut them when I take them off the chassis to paint. 

Couldn't achieve a fit top and bottom, so will have to tickle it from the back with a mallet

I also had to seek Peter's advice on the side panel of the engine bay, as I couldn't seem to make it match up. That's when I realised it's supposed to sit proud to give a flared "gap" to help engine cooling and airflow

I also did a bit of trimming top and bottom to ensure there weren't too many thicknesses of aluminium all on top of one another. I think 2 would be the maximum (without it looking a bit odd and having to use massive rivets) so particularly where you have the two side panels and the scuttle all meeting, I've notched a few out to make them fit neatly.

I should point out that I fully expected some fettling for this part - after all, it's a hand-built car, and that's part of the fun, and certainly the reward when it's finished. Nothing too drastic required at this stage either, no more than the odd nick with the tin snips and a file.

So after this day's effort, and all but 2 panels fixed into position (side panel is still on back order) and fully drilled out, we're looking like this:



End of part 1!!!

Incidentally, I'm logging a sort of FAQ for my build, with photos. It's in excel format, and I'll try and work out a way of putting it on, or at least sharing it with anyone who's interested. If anyone is interested, let me know...