All Aluminium 1957 250 Testarossa - Page 6

Lucky@LeMans · #1 27th June 2018, 22:45

I was hoping to be nearing completion by now but I've had a few set backs, work and home related ( non car related ). But, the old 1700 X Flow is sold. I've got the 4 exhaust silencer boxes made up ready to fit. The front body work is getting close but still needs more work ! Its all moving forward, slowly !

Lucky@LeMans · #2 14th August 2018, 22:56

At last it looks like I can carry on with this project, I should have a clear run at it now right through to completion !
Progress over the summer has been really slow so I need to catch up, I'll be posting updates and photos every week, I hope.
I have fitted the Cologne V6 engine to the existing type 9 gearbox and fabricated new engine mounts. The thermostat housing clashed with a chassis member so I had to make up a 20mm spacer, other than that it went in ok.

Barber · #3 15th August 2018, 09:56

I hope that some rapid progress on the car makes up for the other setbacks. Looking forward to the next instalment.

Lucky@LeMans · #4 6th September 2018, 19:44

A little progress to report at last ! I've made a start on the scuttle panel which was missing from the body when I purchased it. A little involved as I've had to make a wooden former to get the double curved profile correct on the bonnet return edge/lip. This former has allowed me to shape and profile the aluminium panel, its worked out quite well.
I've also removed the original wiring loom. On inspection it was a bit of a compromised birds nest. It was going to need extending, chopping and modifying a fair bit anyway so I decided to start from scratch. The new loom is going to be very simple, even compared to the "7". There are no wipers, no washer bottle, no electric fuel pumps etc, this will be an ultra basic loom with just lights and a couple of instruments to worry about. The Ford column stalk controls are gone and simple switches will be fitted on the dash as per the original TR.

Barber · #5 7th September 2018, 08:12

No heated seats then.��

Lucky@LeMans · #6 7th September 2018, 16:56

A few photos of the work I've done over the last week or so.
The curved box formers have made easy work of the bonnet return edges.
The scuttle panel along with the roughly formed bonnet edges sitting in place. A bit more work needed on these parts before final fit !
The engine has been in and out a few times, next time it goes in should be the last.
The interior is stripped back to bare bones and cleaned up. Also welded up all the holes along the top chassis rail where the old Locost body was rivetted on.

molleur · #7 7th September 2018, 18:27

Very nice work!

Paul L · #8 8th September 2018, 05:48

Daft question time...

Is it just a case of hammering the metal around the former?

Or do you need to apply heat / do something else as well?

This really is going to be stunning when finished.

Good luck, Paul.

Lucky@LeMans · #9 8th September 2018, 09:13

In the case of the scuttle panel it is a fairy simple shape so the aluminium will easily form and stretch over the former around the bonnet return edge. Its easy to work as its quite soft and malleable. I use a domed plastic mallet so you can form the internal radius's . Luckily I had the screen and frame which allowed me to get the correct profile, it would have been guesswork without it !

Lucky@LeMans · #10 10th September 2018, 21:22

Made another former tonight, a concave one this time. I want to get the front end ready this week so it can go back on the car at the weekend, that's the plan anyway !

Lucky@LeMans · #11 11th September 2018, 16:29

A few more jobs done. I needed to make up several curved steel tube sections to support the front end so I looked at buying a tube roller. Most of the ones I looked at that would cope with 5/8" diameter tube were too much money at £300 +. There's plenty of scrap bits of steel lying around in the garage so I've knocked up a simple one for free ! I made a couple of sets of dies so it will do flat section and tube.The first section made will go under the front edge of the scuttle, the ali being formed around it. Here are a couple of photo's...…….

molleur · #12 11th September 2018, 16:51

Very nice work!

jones · #13 11th September 2018, 22:42

Loving it!

Lucky@LeMans · #14 17th September 2018, 16:47

All the return edges around the bonnet are done now. The front end is ready to go back on the chassis and the bracketry made up to support it. Another week and the front end should be just about done ( minus the bonnet itself ! ). Next jobs include a new wiring loom, exhaust manifolds and system ……..

scimjim · #15 17th September 2018, 21:50

Just catching up on this great build and it’s looking lovely

You said you just bolted the new Engine onto the existing type 9 - But the V6 needs a longer input shaft and has different ratios to the 4 pot.

Lucky@LeMans · #16 17th September 2018, 22:11

Quote:

Originally Posted by scimjim

Just catching up on this great build and it’s looking lovely

You said you just bolted the new Engine onto the existing type 9 - But the V6 needs a longer input shaft and has different ratios to the 4 pot.

I found a supplier who has "short" aluminium bell housings available to allow the Type 9's with the shorter input shaft to fit. Well that was what the seller told me but I found out after that he also supplies a spigot bearing adaptor that I needed too ! What I've gained is a light weight bell housing that needed adapting anyway.

Yes the ratios are slightly different but that shouldn't be an issue. With the 80 profile tyres rather than the 50 series fitted to the "7" the ratios in the box and the diff will complement the V6.

scimjim · #17 17th September 2018, 22:20

I’ve seen the adaptor shafts but would definitely go with the short bellhousing (I sold mine for a lot more than I paid for it!).

The change in tyre profile won’t totally hide the very low first (I had a 2.9i GTC with a type 9 and went from 14” to 15” Wheels and first was still only for pulling away on hills) - I’m about to change mine in the hillclimb SS1 for next season as even on a CVH it’s too low.

Lucky@LeMans · #18 17th September 2018, 22:54

I'll have to see once I've got it on the road. I only intend to use it on the road anyway so normal driving, mostly in 3rd, 4th and 5th will be ok, as long as my calculations are correct.

kevemm · #19 18th September 2018, 08:33

Its looking fantastic!

Lucky@LeMans · #20 25th September 2018, 19:30

I've been working on getting the front end bolted up to chassis over the last few days. It's quite involved getting it all supported correctly, I don't want to have any part of it under any stress loads so I'm having to brace it all up. I'm doing it in such a way that none of the supporting structure will be visible.

I've also sent off the log book V5 to be updated with the new body. Should all be ok with what I've asked for under make and model. They have before and after photos, receipts, the old V5 and a covering letter. Wait and see what they come up with.