Untitled Document
  • 26th October 2013 – Rear bulk head panel

    rearBulkHeadPanel3

    The next job was to make the cover panel the SVA Seatbelt frame. We decided to use thin plywood sheet for the actual cover panel which we eventually plan to cover in carpet. This is important and needs to be done for the IVA test as the frame has too many sharp edges and trap points. So we started by making some cardboard templates to cover the frame. Once we had  the template we marked it up on the plywood and cut it out. Additional holes are needed for the frame bolts and seat belt mountings.

    Then just to finish it off we decided to spray it up black. This isn’t necessarily required as we eventually plan to cover this panel in carpet.

     

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  • 26th October 2013 – Re-making the inner door panels

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    We had made and fitted the inner door panels in November 2012 (you can read post here). we had originally made these panels from some spare sheet aluminium that was left over from the heat shields in the engine bay and had fixed them in place with 6 screws on each door. Having had a think about it, we started having concerns that the raised screw heads and metal panel may cause potential rubbing points which then may cause markings on the door leather trim once it was fitted. So we decided to take off the original panels and re-make them in hardboard, this time making sure that when they were fitted they would fit flat with the profile of door. This, we hoped would remove any problems for  potential rubbing points.
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    So as we did previously, we  made a simple cardboard template based on the shape of  the recess in the centre of the door and from that  made 2 pieces from hardboard that exactly fitted.
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    Back in November 2012 we had also  begun to fill the doors with expanding foam. The first time round, we had run out of foam so we knew we would have to go back later with more  foam to get the doors filled to finish this job nicely.  This time we planned to secure the new panels in place simply using the foam so there would be no need for any  screws.
    So once the panels were ready we sprayed the foam deep into all the areas of the door where required and as it expanded pressed  the panels down in position. We used a few off cutted of wood and screws to temporarily secure the panels in place as the foam set. Expanding foam is messy stuff and we did have some over spill around  the edges, but this  cleaned up nicely once the foam was set.

     


  • 21st Sept 2013 – Inner footwell panels

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    We decided it would be a good idea to make a couple of extra panels around the base of the dash and door support frame to finish things off nicely in preparation for the carpeting. These panels would give a backing for the carpet inside the footwells and we felt would give a better finish when the carpet is fitted. Before the carpet goes in, we also thought that we might try packing foam in between the panels and the body to further the sound deadening effect and adding to a more solid feel around the doors.
    We firstly made some templates from card, before cutting them out to size in 4mm aluminium sheet. We decided to countersink the bolts to achieve a flush fit in order to avoid seeing any fixing through the carpet and to avoid any potential uneven carpet wear in the future. We decided to use riv-nuts as a easy way to secure in place, so after a few small final adjustments we drilling the frame, inserted the riv-nut and finally bolted in place.
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  • 1st January 2013 – Interior panels filled with expanding foam

    We haven’t had much of a chance to get on with stuff for the last 2 months due to christmas and other things, we hope to get the build back on track again very soon.
    We had made inner panels back in November to fit around the doors so on New Year day, Mark did find some time to start with the expanding foam he conveniently bought me for christmas.
    We decided that we would like to run the wiring loom between the front and the back behind these panels to keep everything neat. So Mark decided to get some 20mm wiring conduit tube from screw fix that we could fix in place that will eventually have the wiring loom running through it. Due to the position of the vertical strengthening bar at the rear of the door, he also had to cut a hole in the panel that lined up with the end of the conduit, which is where the wiring will exit. He also made made another end and top piece next to the door hinge to prevent the foam coming out next to the hinge before sealing all the gaps with duck tape and putting the screws in the door latch bracket to stop the expanding foam coming out of the threads. The final thing was to drill small holes along the panel to squirt the foam through.

    When squirting the foam our advise is the proceed cautiously and do it a bit at a time. Mark did put a bit too much foam in the front as you can see on the pictures, but if that happens you can slow it down by spraying water on it.
    Once the foam was all set Mark could then remove all the tape and tidy up any extra rough edges using a scalpel blade.


  • 3rd November 2012 – Making inner door panels


    The final job for the day we decided should be to start the interior. Having spoken to Gerry and a few 289 members a while ago, they suggested to get the best possible finish in the interior would be to fill in the recesses in and around the doors using patterns and expanding foam. This we hope will give the doors and body a much more solid sound and feel when the doors are slammed shut. Stewart Clarke also decided to do with his build.

    So we set about making cardboard templates for the door panels and the areas around the doors. We had some spare aluminium sheet left over from the engine bay heatshields so decided to make the door patterns out of this. We then secured into place using double sided foam to make a decent seal and finally screw into place on the doors using 6 screws. We will eventually drill small holes in this panel to fill behind with the expanding foam.

    The patterns around the doors were a little more tricky to get right. We made 2 parts each side, one below and around the doors and a second part to fit and fill the area above the door latch. As these shapes were a little more complex, we decided it would be better to make these from a spare piece of hardboard Mark had in his shed rather than in the sheet aluminium.

    We hadn’t got any expanding foam so we haven’t fully fitted them as yet, but eventually we will drill small holes in the patterns and fill behind them with the foam and fixing them into place. More to come on this in later posts.