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hotrodders.com: Project Journals: Ianmerry's Journal
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View Ianmerry's profile Entries: 253
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10-21-2007 02:28 PM Oct 07
The drivers door was then glassed over around the outer frames and across the window slot with two layers of mat. After curing the slot was cut out where the steel frame sits and carefully sanded down until it lined up perfectly with the steel edge.
The passenger door is shown before the final layers of mat are laid over the inner skin.
All the surfaces will then be sanded down to give a good key for the filler [bondo] to adhere to.

The next stage will be to build up a 1/8" layer of clay over the inner door skins so a mould cane be taken off. This will give me accurate door recesses which I can then fit to the shell.


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  [Entry #98]

10-21-2007 02:16 PM Oct 07
After bonding the steel frame into the carcase using self tapping screws and mastic, the inner sufaces of the frame were sanded flat removing all the excess mastic and threads from the screws.
The doors are now ready for glass build up to the steel frame.
The third pic shows the stainless edged felt window runner I will be bonding into the door after the car is painted.


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  [Entry #97]

10-21-2007 02:09 PM Oct 07
Inner door skins and window runner fabrication-
Previously the door had been strengthened using steel box and square bar so the structure is very sturdy with no flex whatsoever.
But to be sure of no binding under window operating and to keep everything straight and true I fabricated a steel frame for the window glass to run in.
These were made from 3/4" box cut, welded, cut, welded until the shape matched that of the door carcase


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  [Entry #96]

09-15-2007 03:50 AM Sept 07
www.manxyanks.com
are in the big time :-)

The club website has been spotted on the web by an eagle eyed Custom Car magazine reporter.
This came to light when an Isle of Man resident contacted Steven "Knightrider" Dallimore our founder member/IT wiz/chief sheriff, with an interest in building a Hot Rod.
Stay tuned for maybe another manx willys



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  [Entry #95]

09-15-2007 03:32 AM Sept 07
Unfortunately due to the fact I was driving the car and my son Lee was keeping an eye out for the unexpected, no pics were taken of the first ever run under it's own steam.
Electric power steering, air ride and cooling systems were operating fine. But problems were discovered with the battery/electrical system.
In moving the car out of the garage [tight turn] I had to stop and restart the motor 4 or 5 times. This drained the batteries power resulting in a few 4 letter words and a replacement battery courtesy of my employers van!
The 135amp alternator gives out a good 14.1 volts with the engine above tick over with all electrical items on load, so no problem with the charging side. A new larger output/storage battery will have to be purchased.





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  [Entry #94]

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