Somewhere over the Rainbow.

[Blackpopracing]

Thanks Ian, appreciate your thoughts.

[Blackpopracing]

I've been mostly busy with decorating the last few days but got a few hours on Phils car today.

The bootlid panel was the next one on the list as it was nice weather,



and finally the last one - the drivers side reap panel.



Just the infill peices at the B posts to be made and glued to the rear panels and it will all be ready for trimming.

1193 hours

[pop-up]

Hi Mark Thank you for carrying on with this informative and entertaining thread, looking back through the build I didn't see any mention on how you fitted the door window trims, from the photographs you've posted there seems to be no obvious fixings, I know the bakerlite ones are screwed in how did you fit the one's on Phil's pop please? Keep up the good work, many thanks, John Weatherby

[Blackpopracing]

Hi John,

The door window trims are the original bakelite ones, just painted. They are screwed on as per standard.

[pop-up]

Hi Mark Thank you for your reply, I've put my decent glasses on and can now see the screws, my doors are at the back of my shed so will have a better look next time I'm in there. cheers john

[v8pop]

Mark, what thickness is the plywood please? (If it was mentioned earlier then I'm obviously too old to remember or too lazy to look back )

Cheers Tim W

Sent from my M2103K19G using NSRA mobile app

[Blackpopracing]

Hi Tim,

Ply is 4mm.

[Happydaze]

I've never really managed to successfully cut ply without splintered, tatty edges. Sure there must be some tricks, like fine blades ( or having it cnc cut = routed?) but haven't tried to research it further. And neat holes, same problems!

Chris



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[nakedtrimmer]

[QUOTE=Happydaze;612726]I've never really managed to successfully cut ply without splintered, tatty edges. Sure there must be some tricks, like fine blades ( or having it cnc cut = routed?) but haven't tried to research it further. And neat holes, same problems!

Chris

chris ive always used Bosch T101AO jigsaw blades for cutting thin ply wood splinter free clean cuts.

cheers Michael

[malstbird]

I am doing some door cards at the moment. As they are quite large (heavy) on a 32 3W I managed to source some 3mm ply. To cut them I have used the fine blade in my multitool. Its noisy but no huge splinters, just a quick going over with some sandpaper.

Mal

[Blackpopracing]

I've never really managed to successfully cut ply without splintered, tatty edges. Sure there must be some tricks, like fine blades ( or having it cnc cut = routed?) but haven't tried to research it further. And neat holes, same problems!

Chris



Sent from my SM-T515 using NSRA mobile app

A fine tooth blade in the jigsaw and cut slowly. Drilling, use a centre point wood bit and keep the plywood tight to a block of wood underneath. Again, drill at a low speed and don't press hard. Thin ply is generally poor quality though so will always splinter a bit.

[v8pop]

Hi Tim,

Ply is 4mm.

Thanks Mark.

Cheers Tim W

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[Blackpopracing]

It was my birthday today so I celebrated it by doing a bit of work on Phils pop

I am now officially a (miserable) old git but at least I get free prescriptions

The prototype side panels got chopped out where the heater outlets are and panels with correctly sized holes were placed over extra long tubes from the heater and fixed in the right place. These can now be checked for dimensions and correctly positioned panels re-cut.



The heater vents fit snugly in the machined holes and can spin round for airflow direction. I'll cut some new panels tomorrow.




1194 hours.

[Blackpopracing]

I had to move Phils car today to get mine out to clean it as it's having a trip to the seaside tomorrow

It was as I tried to drive his that I realised the drivers footwell trim panel will have to be changed. There is not enough room between the brake pedal and the panel for my shoe! A MkII version will need to be made with a hollowed out bit built into it.

Molly the dog cat (she follows me everywhere) keeping watch over the cars.



The centre console side panels have been re-programmed and machined out, so over the last couple of evenings I've glued on wood strips for them to screw into and got the heater vents and speakers fitted.

It's now mostly finished, the sides will be trimmed in carpet and I'll probably fit an aluminium trim around the edges to cover the carpet edge to finish it all off.



1195 hours.

[Blackpopracing]

Took my pop to the Bagshot breakfast meet today and then on down to the Hayling Reunion meet at Hayling Island.

Pleased to say that even with some 70mph cruising down to Hayling it did 20.9 Mpg which is excellent.

I didn't really bother with photos (everyone else seems to take 1000's now) but here are two.







When I got home I spent a bit more time on Phils car.

Time to sort out the messy wiring that I had not sorted previously (it was bodged just so Phil could make a big show last year);



My trusty assistant Molly was on hand to help out as usual



Looking much better with proper connectors. The red scothcblock is temporary and will be deleted in the future.



And mostly finished.




It's a bit square at the front and I'd like to see what I can do about that in the future. Some aluminium trim will be added around the edge and the sides will be carpeted.



1198 hours.

[v8pop]

Nice day for it Mark. Centre console looks well at home mate.

Cheers Tim W

Sent from my M2103K19G using NSRA mobile app

[Blackpopracing]

Phil brought his pop back round today so we could start the interior trim - finally!- only 10 months since it was last round for work.

A quick reminder of it;




This is where the wood panels had got to: painted with waterproofing compound.




With the wood panels removed we started cutting the trim material to size.





Drivers door & boot panel shown here;





Door panel cut to size and bonded to the wood panel





and back on the car;





Bootlid panel finished and refitted,











Passenger door panel completed and refitted to the car. It may not look much but this was 7 hours work!





1205 hours.

[v8pop]

Looks well tidy Mark, Phil should be pleased with those mate.

Cheers Tim W

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[jsf55]

Custom made straps Mark ?

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[Blackpopracing]

Tim,

Yep, like a dog with 2 tails

John,

Yes, Phil bought the material & I made the straps.