Prepping for Paint - Boot Lid - Part 1

Know your limits!

There are times when building a rod that you need to understand there are limits to what you can do and this can be for time, a lack of required skills or a lack of required tools.

With things like the boot lid on the Pop (and indeed the repairs to the doors) it just didn't make sense that I should tackle these. Yes I'd love to be able to make panels and roll up a new boot lid skin on an English wheel, but I don't have the skill to do that, the tools to do that or the time to do that.

Yes one day I will go down that track, but not on this project. The self placed deadline is early next year to be back on the road, so it would be futile to even attempt. I think this is where some people go awry with their projects and things go from being a quick paint to a 10 year rebuild or worse still, they never see the light of day again. I can't afford to let that happen as I have a Coupe to get back onto building as soon as the Pop is back on the road.

So off I toddled to Steve Simpson at Panel Restorations in Hillside Road on the North Shore.

Yes I had to pay a wad of cash, but the job is being done and I can keep progressing.This is the inner boot lid after repair.

You can see here the boot lid I had was a bit the worse for the 60 odd years it has been in existence. The rusted piece was cut out and the newly fabricated item installed.

This was the first trial fit to make sure all was well before progressing with fitting a new skin.

Steve made a few more alterations to get everything sitting just right.

You may have seen Steve's truck around. This thing is way cool and despite several offers to buy Steve remains the proud owner!

Look Steve up if you are in the area, even if its just to review the projects he is working on. 

Anyway, here it is now all fitted up with the skin installed.

I now needed to create a mechanism for boot release as I am not going to run an external handle. Instead I will have a boot release inside the car. There is one on the existing boot lid but I wasn't entirely happy with it so wanted to create a new one.

It uses the existing catch but instead of a handle with a square shank into the catch, I will have a cable operated lever on the inside of the lid. To achieve that I have put a bolt through the hole that has one side flattened off with a file. I have put red marker on the end of the bolt to accentuate that for you.

I then made a lever and drilled a hole one end that will go over that bolt. I then welded into that hole on one side and filed it so that the hole has a flat on it to match the bolt. (see hole at bottom of pic)

Here it is on the catch. As you can see, when the lever turns now it will also turn the bolt. On the rear of the catch I tacked the bolt head in place so now as the bolt turns it operates the catch.The reason I used a bolt here rather than a square shank (like the original handle was) is so that I can screw a nut onto the threaded bolt to hold the lever in place. I need the arm to be removable so that I can slide the catch unit out if ever there are any issues with it. I wouldn't be able to do that if I had a lever welded to it.

For the other end I raided a control rod and the nylon fittings from a Japanese car. These nylon fittings just press in.

When you press the rod into the fitting it locks it in place so the nylon fitting wont pull out.

Then the nylon fitting is turned to clip over the rod. Sorted!

There we have it. A lot more robust than what was there before and should be relatively trouble free.

Until next time!

Prepping For Paint - Widening Rear Guards - Part 1

One thing that has always bugged me with the Pop is the fact that the tyres sit out beyond the lip of the guard, not majorly so but enough to annoy me. 

Add to that the fact that the guards had been bonded to the car and had started to crack and break away. 

Also things weren't that good underneath with the guard stay having broken away. Yep they needed a bit of attention. 

For me, because I'm quite happy working with fibreglass, the logical option was to get some new fibreglass guards and work with them. 

First up I removed the old guards. A few rusty bolts requiring penetrating oil, but apart from that they came off relatively easily thank goodness. 

Once the old guards were off it was on with the new. Firstly I just held them in place and used a pencil to mark the line on the guard to show where each mounting hole was on the car. You can see down in between the car and the guard where these are. 

Next was to mark where the hole was in relation to the outside of the car. You can see here that they are exactly 1 inch (25mm) to the centre of the hole. 

So I need to measure in from the body line on the guard, out onto the mounting flange. 

I drilled the hole slightly bigger than required so that I would have some movement if things need to adjust forward/back or side to side. 

You can get away with a slightly bigger hole so long as you use a large "penny" washer to spread the load. 

Here we are with the first guard mounted. A little disappointed that I am not better off with these guards than what was on there originally. You always hope that things will be easy, but no surprises when they're not.

The gap to the body isn't too bad though, so a bit of fender welt from Basis down in Renwick will do the trick. I won't bond the guards to the car as having them removable isn't a bad option to have if ever I want to remove the diff for example, but it also means I won't have a repeat of the join cracking like on the old guards. 

Here's the car with both guards mounted. Best part of about 4 hrs work here. 

The next thing is to widen the guards. Never done that before so here we go. I figured if I came out from the body a bit (so I have room to run the jigsaw though the cut) and be somewhere near the centre of the guard at the top where there is minimum shape/curve it will then be easier the blend the shape of the join. 

I used one of my trusty dense foam blocks to mark the line with a pencil. 

I then hacked into with the jigsaw. When doing this, use a steel cutting blade, fibreglass is harder than you think and a wood blade will be blunt in 30cm. 

Halfway up the cut I stopped and clamped the now loose bottom edge just to keep everything in place. 

Once cut completely I clamped the front edge also. I was then able to pivot the outer part in and out until I got the desired width/look. 

I then clamped the guard in the middle also. The aim now is to grind away at the edges (between the clamps) to get a good bond. I'll talk about this a little more later on with a few drawings to demonstrate. 

Hang on a minute though, that's not going to work! How will I get the centre clamp out once I have glassed either side of the clamp and everything is rigid. Nearly a fail!

Instead I substituted the centre clamp with masking tape and a dense foam block folded back on itself. The block pushes the gap open and the tape stops it opening any wider than I want. Really easy to work with and infinitely adjustable. What's more it's nice and firm. So much so that I was able to attack the edges with a grinder without anything moving. 

Now about prepping those edges. The idea is to maximise the bonding surface area. Let's look at some cross sections. 

If you have two square edges and glass them together like this....

..... once you sand off the surplus fibreglass you will end up with a very small connecting surface and a thin layer as highlighted. This will crack. 

To overcome this you need to taper the edges like this. 

Then once you have glassed and removed the surplus you will end up with bonding surfaces as highlighted below. This is much stronger and there is no straight edge in there that will crack.

So here we go, lets start fibreglassing. You can put packing in behind but I found just adding one layer and letting that go hard first, then putting on the extra layers from above was easiest. 

Not looking too bad!

If it starts to look like rain, cover the curing fibreglass. These plastic sheets are good as they are waterproof and they peel off if they make contact with the wet fibreglass.

Its important that no water gets in, as water kills the chemical reaction, and your fibreglass won't harden.

Once done I took the guards off and flipped them over to glass the insides. Here we are after sanding. All set now for a bit of body filler and priming.

Until next time. Remember you build a rod by doing. Even if it's just 1/2 an hour of pondering how you will attack it, or 1/2 an hour on the internet finding parts. Every little thing you do is progress. Watching TV isn't. Get in your shed!