ALRC Project

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jai_landrover said:
Wouldn't consider anything other than an msa legal cage as worthy o the title of roll cage anything else is just unwanted weight and scrap iron

We all know you might be able to fool the scruteneer you can't fool the air ambulance
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I wouldn't build anything other than a MSA spec cage unless it was say for an expedition vehicle for abit more protection but I would still make it as strong as poss :)

Considering a full tube racer for the next project :)
 
Hi Guys, I'm doing some paneling this week, and. I have had an interesting day today up at a friends (Julian) who has some 4 foot rolls which I used to roll my roof skin. well Julian makes exhaust systems and he has a 1974 Surtees TS 16 in for which he is making a full exhaust system, trying to get under 107 db and not succeeding. It seems it is the engine that is louder than the exhaust. He actually rang Cosworth and asked them how loud a DFV is and they said they had no data :confused: which seems strange.
The guy that owns the car has 3 F1's which he wants restoring, and one of them he has snapped in half :eek:

Anyway back to my project. I have rolled the roof skin and have annealed the edges and corners, I will have a go at making it fit tomorrow. Also today I made a side skin which now needs fitting and final shaping.
I have also got some welding done on the fuel tank and inlet manifolds, Pics on them latter.


 
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Earlier in the week I made up some rear panels some of which are loosely fitted for now.
The vented tailgate was time consuming too make, all beaten by hand.




 
Boris113 said:
Great build, I am very envious of your fabrication skills!

Would you mind explaining how you made the side skin and in particular the lip around the wheel arch?
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Aluminum is pretty easy to work especially if you anneal it. To do the curved flange I cut the panel out with a jig saw, them marked the wheel arch curve on the inside. I then folded the straight top edge to help keep the panel straight, then put the panel on my welding table outside down with the wheel arch lip over the edge of the table. I put a heavy piece of angle (with no sharp edges) on the panel near the edge to be folded and worked around the edge with a selection of dollies hammers and mallets (wood and hide mallets are best) because of the way it is curved you will need to stretch the flange in various places with a planishing hammer to keep the panel flat and if the panel work hardens as said anneal it.
do this with a gas torch/blow lamp, draw on one side with soap and heat the other until the soap turns black and leave to air cool.
 
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Hi all, another update. I have made and fitted the roof panel, it took me a whole day. It may look like a flat panel with the edges turned over but there is a compound curve at every corner, then there is getting a nice neat overlap onto the roll cage which you have to work out before beating it over the cage and at the same time as doing all this keeping the center section flat.
I know I will probably run it straight under a tree branch at the first event and dent it in but at least it will start of nice.
The last one I built a friend help me so I let him double enter the first trial and on the second section I did a right turn then up a slippy bank which I only just got up so I told him to give it some of the corner, well he did just that straight into a tree about 15 foot of the section :rolleyes:

 
Then I have made the other rear quarter panel. The top edge is just bent over a piece of square box. That is the panel below the door in the pic.



And these are all the tools I used to do the wheel arch plus I had too anneal one small section to make the curve in the outer part of the panel.



and the finished panel with a joggled edge.

 
200tdi ayre said:
Something I really want to learn is how to beat panels properly :)
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I only know what I have picked up of my Dad. He did his apprenticeship at Paramount motors in Swadlincote. they used to build complete bodies on Triumph roadster chassis, The bodies they built looked like an early Healey.
I have seen me Dad make a front wing for a Mk2 Jag from scratch, curves in every direction.
 
owl said:
I only know what I have picked up of my Dad. He did his apprenticeship at Paramount motors in Swadlincote. they used to build complete bodies on Triumph roadster chassis, The bodies they built looked like an early Healey.
I have seen me Dad make a front wing for a Mk2 Jag from scratch, curves in every direction.
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Would just have to be something you learn by watching and doing :) and a lot of waste aluminum :rolleyes:
 
Looking nice Simon!


I just painted my flat rear quarter tailgate panels in the dark. Not looking anything like your artwork!!
 
owl said:
No in several, part on folder, rolls and wheeling machine and part on sand bag then gas welded together planished and finished off with spoons and file.
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Yeah was thinking had it been one piece that would be massively impressive. Making it at all, no matter how many pieces is still mighty impressive. Certainly something I want to have a good go at one day.
 
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