Saturday, July 23, 2011

Here's a little bit of the recent work. Around the door and window apertures I've added one or two plug welds between every factory spot weld.

Cut some templates to the inner roof skin shape and had some RHS bent up by Dydo manufacturing. These were for bracing the roof, and I had figured I'd tie the roll cage into these braces where they joined the sail panel structure. However I now plan to tie the main hoop to the sail panels via the upper seat belt mounts. That would make the horizontal brace unnecessary weight. And the roof is one of the worst places to add weight. So now I'm not sure I'll use these at all.

I milled them full of holes on one side to lighten them. I drilled the bottom of the horizontal piece thinking that I wanted the maximum surface area to glue to the roof skin with panel-bond epoxy. However after thinking about it I decided the upper surface was a better choice as there is still plenty of area for the roof skin to bond to it, and the weakening from the lightening holes would be offset by the roof skin. So I milled the holes into the top of the diagonal piece.

Here they are sitting in place, they fit up against the roof skin perfectly. If I did decide to use them I'd get another horizontal piece made up and drill the upper surface.

They were a good exercise, but they seem unnecessary now and I won't be adding them.

I've added a handbrake to get rid of the shit, factory, foot operated parking brake. Plus the subframe connectors get in the way of the factory underslung cables. Don't know if the parking brake mechanisms in the drums are up to handbrake slides, but it would be fun if they are.

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