Started bonding the shell onto the wooden chassis. Epoxy Resin was mixed with a filler material to give it a consistency of peanut butter. This was then spread between the wood chassis and the fibre glass shell before the shell was held in place with a load of self taping screws as shown in photo below.
After abut 4 hours when epoxy had set (but not fully hardened) the screws were removed.
Today I remembered why I hate working with Fiber Glass. Even after showering and putting on clean cloths I’m still itching from the fiber glass. The day was spent with the unpleasant task of grinding away all the old fiber glass that once held the body onto the wood chassis. It took most of the day but its a least complete so I will soon be able to trial fit the body onto the wood chassis.
I have also started shaping the rear parcel shelf so hopefully the body will fit. Hope to finish this tomorrow along with spending most of the day cleaning all the fiber glass dust from the garage.
I’ve been on Holiday for the last week. Although it doesn’t look like I’ve done much I have spent the majority of the time filling and sanding the car. I still think I need to spend one more day to complete this but this afternoon I’d finally had enough of sanding so I wheeled the car out of the garage and washed it down. When you do this what looked ok in the garage suddenly looks a lot worse. Maybe I shouldn’t t have used the pressure washer but it highlights all the small air bubbles you can get when you apply the filler.
Well I’m back on Holiday again. Today was spent welding up the petrol tank. This actually took four attempts before we finally managed to get it done without it leaking. The tank doesn’t look great as it has distorted quite badly from the heat but so long as it’s not leaking that is all that really matters. To try and really ensure I don’t have any problems with the tank in the future I also used a can of petrol tank sealer. This was pored inside the tank and the tank was then slowly rotated around to try and get an even covering of the sealer over the inside. I am also hoping this will help stop the tank rusting again.
After spending a long Saturday filling and sanding the car it is now a bit closer to being ready for paint. I still think I have several more days of sanding the car as it is taking much longer than expected. Instead of continuing with it this week I have decided to spend the rest of the week (and my Holiday) painting the underside of the car. To do this I spent the afternoon removing the shell from the chassis. As well as painting the underside of the car I also need to waxoyl the chassis before I put the shell back on. I could always waxoyl the chassis later but it will be far easier with the shell removed. I hope to have all this completed by the end of the week so I can put the body back onto the chassis before I return to work. As well as these major tasks I have a list of much quicker and simpler items that need to be done such as having some parts shot blasted and painted and to finish the exhaust system off. The main item that needs to be done with the exhaust is to move a bracket. This needs to be done now as it will not be possible to weld it once the shell is back on.
