body parts

Everything regarding bodywork and materials like fiber glass etc...
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stylussprinter
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Re: body parts

Post by stylussprinter »

Fitted the passenger side bottom shut ledge. All clamped up so will fit the drivers side Monday ---- off to Rushmoor Dimanche Sprint tomorrow to spectate :roll:
Been wading through loads of Dzus , Camloc and other quick release mechanisms , in various brochures and online sources but not made up my mind yet :roll: I like the idea of the Camloc ' press fit ' but not sure they will hold and not vibrate loose :?
The flip will be held in place by two bonnet pin catches , one each side of the gutter by the screen as before so the side catches would be there just to stop the wind flapping the sides around.
Any thoughts :?:
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
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Antnicuk
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Re: body parts

Post by Antnicuk »

my cousin has the orange pheonix here with a flip, it has ali ledges with dzus fasteners but they kept coming off with vibration and flex. Not sure what the cam lock ones are. As said, i chose the big fat rubber hooks as i couldnt find anything that i could trust but i know they are not the prettiest.

Dzus do another type of slide fastener that i have used for my hood rail which i think are meant for bonnets, they have pin with a grove in it and on the outside panel you rivet a very small sliding mechanism which slides and locks in place. My rx7 used them as bonnet pins and they worked fine. like these

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... 0316646150



The orange car here:

Image



has fasteners like this.

http://cgi.ebay.co.uk/DZUS-fastener-sel ... 240%3A1318
Help! just starting out

Edit: Getting the hang of it............. Slowly
stylussprinter
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Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

H'mm , still thinking :? Tony , Matt had those R888's yesterday -- sorry :roll:
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

Both bottom side shut ledges cut/glued now. Drilled some scrap bits/glued to test out fitting some quick release fasteners that I've aquired before fitting for real on the car. Need to pack out/experiment so's they fit first attempt :roll:
I'll take the clamps off tomorrow to try fitting them , or one of them anyway :wink: Fibre glass will wear I think so might need to reinforce the outside of the panel , even if it shows -- we'll see :roll:
Attachments
progress 530.jpg
progress 527.jpg
progress 529.jpg
progress 528.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Re: body parts

Post by stylussprinter »

Final arch gap cut and drilled ready to widen the arches and both sides old air vents glassed over with P40. I'll fill with P38 and rub them down tomorrow-- bit more progress :)
Attachments
Final cut.jpg
Drilling ready to glass the arches.jpg
Drivers side vents filled.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Re: body parts

Post by stylussprinter »

Rubbed down , filled with P38 and rubbed again . While that was setting , I fitted the alloy tabs with rivnuts ready for the light covers . There's not going to be any lights but the front looks naff without the covers. When they're really gone off hard , I'll be able to adjust/bend them exactly parallel to the ' cover ' under surface. If they aren't just right then the ' cover ' is under stress when bolted tight with the flush fit countersunk bolts (3mm).
The tabs were glued to hold them still then fixed with P40 . After that I put one layer of 100mm square matting/resin over each one.
Attachments
Alloy tabs to fit ' covers '.jpg
Drivers side.jpg
Passenger side.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Re: body parts

Post by stylussprinter »

That's it for today . Fitted one ' cover ' :D Don't be fooled by the ' light ' on the clean cover --- the tab's are behind it but they do look as though they're on top :wink:

Once it's painted , I'll do the F/Glass behind the covers in black as before.Makes the covers appear darker & you can't see the lack of lighting :)
Attachments
Cover drilled,tabs adjusted & in.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

I've gone about as far as I can go with the shutting edges . Drivers side is very close and the passenger side too apart from the lower horizontal shut. That's about 3mm but once the paint's on it'll look fine :)
Both headlight covers are on now but they'll come off for painting :wink:
Attachments
Both light covers fitted.jpg
Better fit now.jpg
Better fit but bigger gap at the bottom edge.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
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Antnicuk
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Re: body parts

Post by Antnicuk »

looks good rob, what did you use to cut the small slots that the head light cover brackets slide through? i need to fit mine soon.

also, what are you going to do with the arch where you have drilled the holes?
Help! just starting out

Edit: Getting the hang of it............. Slowly
stylussprinter
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Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

Antnicuk wrote:looks good rob, what did you use to cut the small slots that the head light cover brackets slide through? i need to fit mine soon.

also, what are you going to do with the arch where you have drilled the holes?
The slots are just 6 holes with a 3mm drill and filed out . The holes around the arches are so that when I mould up my extensions , some of the matt/resin plus P40 to curve it , gets into those holes giving it a ' footing ' . Then when I've finished the extensions I'll glass behind those holes about 25mm wide all the way round to join up with whatever has gone through :wink: Finally I'll finish the curve with P38 and rub down which is exactly what I did on the original body when I built it or not long after :roll:

The first time I did this I used alluminium and sikaflexed it to the arch after cutting off the amount and shape f/glass I needed then moulded over the alloy with glass and P38. That got ripped out at NORTH WEALD so I then lowered the car again necessitating more cut out. This time I only used the alluminium as a former to mould the extension on. Hard rollbar foam cut into 100mm bits jammed between the tyre and the former then just remove it the next day --- file and finish , job done :wink:
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

Painted the curved shutting ledges on Saturday ' Red ' then today stuck some varying thicknesses of neoprene self adhesive foam along the edges . The ledge does vary in depth due to the piece not being exactly the shape of my old body mould so neoprene helps bring the panels together. This wouldn't happen on a new body converted to a flip front , it's just my ' very ' thin one making it tricky :roll:
Had another sand paper session at the arches too , bringing the tyre to arch gap to an even 22mm's. I had some ' glue ' left so decided to glue kevlar 1mm thick extensions just under them , then fill in the curve once they're set tomorrow & it'll become part of the arch rather than use alloy as a former for glassing ,
When that's done I'll cut a gradual curve from in front of the wheel , out to 30mm then back to behind the wheel .

See the ''alloy former'' method , I used last time it needed doing (after another lowering session :wink: )

I'm getting there slowly :)
Attachments
Getting arches ready to widen 2005.JPG
Passenger side glued.jpg
Glued drivers side arch.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Posts: 3772
Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

All drilled up (the glue ) and two layers of glass so ready to P38 once it's nicely off :)
Attachments
Still wet & untrimmed.jpg
Trimmed back.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Joined: Fri Mar 10, 2006 8:49 pm
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Re: body parts

Post by stylussprinter »

Busy with P38 today --- lots of rubbing down , more P38 etc etc -- very boring :roll:
Attachments
Ready to rub down.jpg
Rubbed down but still needs filling.jpg
P40 securing the overlap.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
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Posts: 3772
Joined: Fri Mar 10, 2006 8:49 pm
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Location: ASTON CLINTON BUCKS

Re: body parts

Post by stylussprinter »

Finished the arches so they're ready to paint , also opened up the grill by cutting away another almost 15mm's from the top and 5mm's off the bottom edge , sides to suit. Helps get more air in.
Can't mount the filter facing forwards as before to get ' ram ' effect because hinging the bonnet and designing a different ' A ' frame means there's not enough space between radiator/frame crossbar and the grill. That being the case , it has to lay across the grill on the drivers side as low as possible so air can flow to the top of the radiator :wink:
That means the sides of the filter are in fact more in contact with the airflow BUT the centre isn't. So I've robbed my old burnt out carbon fibre silencer to make up a scoop to turn the air into the centre of the filter :P
It's tie wrapped through holes I drilled into the steel end then sealed with Sikaflex. I held the curve in place with a tie wrap until the Sikaflex set . The scoop is about 50mm's at the back and 70mm's at the front entry.
Drilled and fitted rivnuts/washers to the underside of the grill top for mounting the timing strut . Problem is ------------ the flip cannot be tilted totally open with the strut fitted and scrutineering expect it to be in place :( There's stacks of space but it's the transition from half tilt to open and the ' arc ' that the bottom of the strut describes before becoming clear. Wheels on planks - flip open - planks removed --- plenty of space , bloody annoying :twisted:

The photo doesn't show the grill cut back . The top was about 45mm's deep so is now 30mm's ish and about 20mm's at the bottom.
Attachments
Ready to paint.jpg
Old carbon silencer handy.jpg
Scoop facing forward.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
stylussprinter
Stylus owner
Posts: 3772
Joined: Fri Mar 10, 2006 8:49 pm
Are you a Stylus owner?: yes
Location: ASTON CLINTON BUCKS

Re: body parts

Post by stylussprinter »

I've been putting off getting on with the bottom shutting fasteners this week due to complications of slightly differing ' old ' body thicknesses. These little fasteners are quite specific in the panel depth they are for although I have got more than one length of allen cap screws now --- cheers Andy :D
What I didn't realise is that although they are called ''quarter turn to lock'' fasteners , you can keep turning untill they clamp which has helped :wink:
I'll need to have the allen '' T '' key kept in the door pocket though in case of the need for FAST flip removal :shock: by the marshals that is :roll:
Attachments
Countersunk screws in front face and spacer at the rear.jpg
Rear drivers side.jpg
White marked to see where hole should go in the flip !.jpg
Push and turn allen caps.jpg
I just love the Stylus but she keeps swallowing £££ !
Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.
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