fractalign

Hey Guys. I made up the structure that will become the door frames. The first thing I did was get the dimensions of the frame from the 1:1 door. The upper part of the frame works out to be 1mm thick. The lower part of the frame which runs the length of the door is 0.8 mm with a 45 degree taper at the front. The taper is in line with the base of the windscreen and this is also where the quarter window is located. Here are the two lengths used. The half round 1mm thick length was turned round side down. A 0.3 by 0.5 mm rectangular strip was attached to the flat side of the half round length.

After waiting an hour or so I gave it a quick sand and here is the result ! It does not look that different but when I run my finger along it I can feel the crease. I will be keeping this tool because I will need it for the other side. Next up I will be concentrating on completing the door frames, and rear windows.

Once the contour was checked, the body filler was mixed and applied along the length of the side. The tool was then used to even it out, I found that slowly and steadily produced the best result. The excess filler was applied to backside where the door skin will be.

I placed the tool next to the side to see how much filler I would need. Very little it seemed.

Hey guys. Spent some time putting this tool together. Its a contour gauge and filler blade. As mentioned previously, I had traced the front side contour of the door. From this 1:1 template I had the the right shape to make the 1:25 scale version. The idea of the contour gauge is that the base slides along the rocker panel allowing the blade to even out the filler in a straight line. I had a few tries of running it along the side of the body to get the feel for it before adding the filler.

Hey Mike. You might be surprised to find my modelling skills are pretty average. As far as undertakings go you only have to look at what other guys have put up over the years to get ideas for a scratch built project. If you look at what these have done, you might pick it up faster than you think.

And here is the result, next up will be the completion of the seam line. This will be most challenging part of this build by a long shot.

This time I used just the modelling knife, even the holes on the curved parts were done with the blade. I rotated the knife like a drill bit to remove these areas, I then used the blunt edge to scribe out the rest of the area.

With the roof on the first side refined enough, the next task was to peg and glue the other side in place. The other side was sanded down to match the roof contour of the first side. Both need to be mirror images. With the two halves still glued in place I began work on cutting out the window area as well.

Hey Guys. I did a little bit more tonight. The first task was to clean up the rear pillar. By doing this I was ready for the next big task. Up until now I have left the other side more or less untouched.

I realised that the roof area was still too thick for the pillar to fit so the final task for the night was to cut the excess area. Here is the result, the windscreen frame was tidied up as well. Next task now that i have cleaned up the inside of the the front part of the roof area will be to repeat this process with the other side.

I also did a bit of work on the door frames. These had me stumped for days but in the end I decided to use two lengths of half round, one 1mm and the other 2mm. The 2mm pace was turned around with the flat side facing out. The 1mm piece was then glued into it with the round side facing out. These were then cut to the length of the B pillar.

Hey Guys. I got a little bit more done tonight. The main thing was installing the channel, I realised this would have to be in two stages because the taper along the side where the door meets the quarter panel is the same as the taper on the edge.

Well I am trying to, what I can't scratch build I will modify to suit. Anyway I would like to thank all you guys for your encouragement, every bit helps !

I like Chevy Nova's so i'll be watching this build for sure !

You might surprise yourself, if you look at enough On the Workbench posts you pickup things very quickly.

This is very cool ! I never realised just how big truck racing was until I saw all those images. Keep up the build, I will be watching for sure.

The last shot shows how the channel will look when attached. The image in the background shows a full size door skin, this is how the channel should look in mine, once its finished. Next task will be getting the channel attached.

To recreate the channel, a piece of 4.5 millimetre round tubing was cut in half. The pencil marking is for the next cut so that the tubing is quartered.

Next task is the channels. I took a template from the leading edge of the of the 1:1 door to check the contour. Anyway on the right of side which is actually the top of the door there is a quarter round channel the runs from the cowl all the way up to there rear drip rail.

After using the angle grinder along top and bottom edges, a few hard taps with the with the mallet at either end knocked out the piece. few hard taps with a mallet finished the job on the front and rear pillars.

The hardest part with removing the window area was not cutting into the A and C pillar. I wanted to retain the windscreen pillar to keep the strength in the roof. Wood working tools are perfect solution.

Hey Guys. I did some more today. The first thing was to mark the holes where the window area was removed.

A real surprise !

That really works, especially the Ardun !