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I would like to congratulate you and all the other Sportster builders (inc Patrick and Richard) for keeping your web sites up to date with such detailed pictures and advise. It is a great help to others either building or thinking about building to know there are so many of you out there willing to advise and to also see what a great job you are doing. Of course it helps that you are building such a well engineered product ;-)
Little bit more progress....
Today, I cut and tested fitted the nearside top bonnet. I still have to drill the other 33 holes for the piano hinge.
After the top bonnets, I just have the front cycle wings to fit to complete the exterior bodywork.
A few pictures here..............(as usual) http://www.flickr.com/photos/peters-bmwmarlin/
I am about to start the process of fitting the top bonnets and I was curious as to why you had to trim off the return on the lower edge?
Cheers
Robin
It's just trimed at the rear edge to clear the edge of the scuttle.
It will be obvious to you once you try to fit them. At the front you just take the corner off to clear the nose cone.
It's just trimed at the rear edge to clear the edge of the scuttle. Peter
Thanks Peter. I looked more closely at your pictures and I can see now. When I first looked I got the impression that you had taken the hacksaw to the entire length of the return!
Can you tell me what tool you found best for trimming the front and back of the bonnet? Is a good old fashioned hacksaw best or is one of these nibbler things better?
Can you tell me what tool you found best for trimming the front and back of the bonnet? Is a good old fashioned hacksaw best or is one of these nibbler things better?
Cheers
Robin
I did buy one of those hand nibblers but I found for me the best method was my battery operated Jigsaw with a nice new finnest toothed blade and a fully charged battery to get the maximun revs.
Having clamped the bonnet to the workmate, take a deep breath and just follow the line slowly. With the jigsaw, you can follow the curve of the bonnet.
By the time I got to the last cut, I was getting real good!
I found for me the best method was my battery operated Jigsaw with a nice new finnest toothed blade and a fully charged battery to get the maximun revs.
Having clamped the bonnet to the workmate, take a deep breath and just follow the line slowly. With the jigsaw, you can follow the curve of the bonnet.
By the time I got to the last cut, I was getting real good!
Thanks Peter
I have a "professional" jig saw (left over from the last major project which was a wooden boat) but I think its probably much too big and clumsy for a job like that. I think I will have a look around in my local B&Q warehouse and see what they have... I need to buy a good new 5mm drill anyway ;-)
I know what you mean about getting to the last bit and getting good. I often feel like I want to do a job again once I get to the end and get proficient at it!
I completed the bonnet tops today and drilled and fitted the 42 nuts and bolts! A back aching exercise if ever there was one.
Also, the spare wheel cover was in the way, so I popped that on as well. It doesn't fit too well, but I have noticed that other cars have wing piping around the edge which I suspect that will cure that problem. http://www.flickr.com/photos/peters-bmwmarlin/
Be warned, my spare wheel cover threaded rod was not in the exact centre, so if you are doing this task, make sure you measure it first!
The car is looking great, but too wet today to take any photo's outside.
I completed the bonnet tops today and drilled and fitted the 42 nuts and bolts!.
Looking good Peter! What are the rubber edge strips you mentioned? Are these something in addition to the rubber moulding where the bonnet rests on the bulkhead and nosecone?
Looking good Peter! What are the rubber edge strips you mentioned? Are these something in addition to the rubber moulding where the bonnet rests on the bulkhead and nosecone?
Cheers
Robin
Yes, i've added rubber "U" section to the front and rear edges of the top bonnets as this was a SVA failure point on Patrick and Richards car. I haven't taken a close up shot but you can see it on Patrick's website under his SVA section. I've used 10mm deep U-section.
cheers
Yes, i've added rubber "U" section to the front and rear edges of the top bonnets as this was a SVA failure point on Patrick and Richards car. I haven't taken a close up shot but you can see it on Patrick's website under his SVA section. I've used 10mm deep U-section.
cheers
Peter
Aha - this is in case you run into anyone whilst driving with the bonnet open...
Did you have to adjust the length of the bonnet to fit the U-section or is it thin enough to fit without doing that?
Just started to fit my bonnet tops today so it would be handy to know.
Aha - this is in case you run into anyone whilst driving with the bonnet open...
Did you have to adjust the length of the bonnet to fit the U-section or is it thin enough to fit without doing that?
Just started to fit my bonnet tops today so it would be handy to know.
Cheers
Robin
I have fitted my bonnets to fit without the U section, as that will how it will be when finished. It is a bit tight with the U section now fitted but it'll be Ok until the SVA.
What size wheels and tyres have you used? It looks as though you were able to fit the front mudguards without having to cut bits out of them to clear the stays - as Patrick had to do.
I'm sure those wheels look different to the ones you were originaly going to use?
What size wheels and tyres have you used? It looks as though you were able to fit the front mudguards without having to cut bits out of them to clear the stays - as Patrick had to do.
I'm sure those wheels look different to the ones you were originaly going to use?
BR
Robin
Well spotted Dr. Watson!
Yes, these are actually the first set of wheels I bought about two or three years ago! They are a set of second hand 15" alloys with cheap 205/50 tyres. I don't have any tyres yet for my wide Borbet alloys and I thought these would be easier to get through the SVA (The Borbets are a bit wide )
The plan is to run the car in on these wheels and tyres and then upgrade to the Borbets post SVA and the final paint job.
regards
I can't wait to see those Borbet on your car with it sat on the road - will look awesome! Mine handles quite well with 205/60/R15 on 7x15J's so I'm not sure what I'm going to so. Probably stick with the current wheels at least until the tyres and worn through!
More wiring, horn relay and door straps fitted today. http://www.flickr.com/photos/peters-bmwmarlin/
and......
Yesterday, I did a bit of experimental carpentary to make some curved infill panels to go behind the seats. The first one has come out pretty good. I need to make another one next week and then carefully cut them to fit round the chassis.
I can't decided whether to cover them in black vinyl leather cloth or carpet? I also need to decide whether to fix them with screws or velcro?
carpet is much easier to work with on a concave shape, in my experience you easily end up with wrinkles using vinyl. However its quite a gradual shape so it might be OK
More wiring, horn relay and door straps fitted today. http://www.flickr.com/photos/peters-bmwmarlin/
and......
Yesterday, I did a bit of experimental carpentary to make some curved infill panels to go behind the seats. The first one has come out pretty good. I need to make another one next week and then carefully cut them to fit round the chassis.
I can't decided whether to cover them in black vinyl leather cloth or carpet? I also need to decide whether to fix them with screws or velcro?
Any views?
cheers,
Peter
Looks like your B&Q plywood did the trick! Good quality vinyl would be my choice - I am not a big fan of to much carpet in an open topped car.
I would fit them using domed head wood screws (chrome on brass). It should look pretty good if you use the little shaped washer thingies (technical term) under the heads.
Robin
Cup washers - that's what I was trying to think of!
Ah - that's what the formers where for - I thought you where building a boat - that or a Moggie!
Looking good though.
Yes, I was quite impressed with my own boat building abilities!
I can now sleep at night knowing that when Global warming kicks in and the sea level rises, i'll be building my Marlin Ark!
I now have headlights that dip, beam and flash along with driving lights that beam and flash.
Well I would, if I had a light switch wired in!
I am sooooo bored with crimping wiring terminals.......and my back aches from crawling in the foot well!
It'll all be worth it, come the spring........
happy building, Peter
(Yes, I know that middle relay needs pushing in properly)
After a number of weeks connecting wires, I got to the exciting bit of testing the dashboard!
Apart from a loose connection on the oil gauge everything seems to be working fine. Can't test the speedo yet, as that sensor is not yet connected.
)
