Roof for Kit Car

[shed or dead]

Hi everyone,

I have mainly been a reader of this forum, rather than a contributor, however I now have a digital camera so thought I'd share some pics of a new steel roof I'm making for my Marlin Roadster kit car.

The original Vinyl soft top had an unfortunate ending involving dodgy fasteners, strong winds, and the wagon lane on a motorway!

So, I started (still nowhere near finished) with the intention of imitating the roof of a Marlin Berlinetta hard top. In the interest of this being a project I actually finish I decided from the start that I will take any short cut, not worry too much about having a perfect finish on the steel etc as the painting will eventually let it down. The original paint on the car is terrible, so the benchmark isn't too high.

Bought a 1500mm x 1000mm sheet of 1mm zintec steel and had the stockist square it up as I wanted to just find the centres and crack on. The length will need to be trimmed but the width is exactly as required.

Rather than build a proper buck, and beat out all the shape for the curved back, I cheated by cutting the metal, and overlapping as the pics sort of show.

 

[shed or dead]

Wasn't sure if the pics would be in the correct place if I kept typing soposting in segments until someone can advise, thanks in advance.

For the rear window I wanted an ellipse shape with a split screen, so googled the maths and ended up needing to make a giant compass for marking out. I used threaded rod with a nail for the pin, and a pen, hose clamped to a stud fastener, which allows for adjustment with a reasonable degree of accuracy.

 

[shed or dead]

Having marked out the window onto Plywood I cut it out using a jigsaw, then squared it up to the metal, and marked the metal. While it was all clamped in place I drilled 2 locating holes, these I will fill with the MIG later, hopefully without too muck distortion as I wish to avoid too much hammer work.

 

[shed or dead]

Those of you who've had a go at Hammer forming by this method will instantly spot that I've left too muck metal for the angle of the fold, and the relatively brittle steel.

Hence the following cracking, but I'm learning as I go along....

 

[shed or dead]

Admin, having trouble posting pics, it tells me that a security token is missing?

Having another go....


And this line of text should be between pics, just an experiment, please ignore.

 

[shed or dead]

Pics loading again, still unsure how to add text between pics?

Here's about where I'm up to at the moment...

 

[Wozzaaah]

Pics loading again, still unsure how to add text between pics?
.

Instead of using 'insert all' just insert each image in turn, press enter and add your text, enter again, insert image, enter again, add text etc.
That will place the images in a column with text below each one.

 

[gavuk]

Good job ,very interested in this ,i have a marlin in boxes,stashed in a shed....what engine do you have ?I have the 2.0litre straight 6 ,gt6 or vitesse engine,never had it running bought as a project too many years ago ......

 

[Wallace]

Looking good so far. Was there a reason for using 1mm sheet as opposed to 0.8mm?

Mike

 

[shed or dead]

Thanks guys, I'm just heading out the door to work now but back at about 23:30 so I'll try to post answers, and get some picks of the car up.

Cheers

James

 

[pressbrake1]

Interesting.
If I have a lot of stretching to do I use 1.2mm sheet and some heat if needed to help it on its way.
As for pie cutting the sides I would have done them in separate pieces gas welded to keep the joint soft, that way a lot less shrinking would have been needed.
Not criticizing , keep up the good work

 

[shed or dead]

Wozahh, thanks for that, but more for your posts, I have learned much over the years.

I extend that thanks too all contributors, and learners, as I am indeed an amateur,and don't be shy like I was, let's see some pictures peeps!



GavUK, I have a Triumph GT6 / TR6 lump, not so economical, but purrrrrrrs beautifully, and a car like this is all about driver satisfaction! Build your Marlin, the dedicated forum will help with parts, but this forum will be so much more help with everything else. Thanks.

Wallace, having checked my receipts, it seems I used 0.9 as it was within my budget at the time. I'm used to bashing 1.2 - 1.5 aluminium but the budget will always dictate. Thanks.

Pressbrake1, I'm interested in your comment as it gives away more than it asks! I currently only have MIG, but would love gas (although would buy TIG if budget allowed). Gas welding lends itself excellently to the 1050 Aluminium
i often occasionally parts from, but I can't justify that equipment as I currently work in a call centre. My aim is to perfect my skills, and workshop, for making custom parts so I can do that in my retirement

Many thanks

Jam

 

[shed or dead]

So, here is 'the beast'...

 

[shed or dead]

Uploading pics didn't go quite as intended but I'll have another go.




The 'buck'.

 

[Exuptoy]

Is the roof going to be at a right angle like the wood? It would look more natural if it were maybe 60-70 degrees with a nice curve instead of a bend. Just my opinion.
Not real clear in the pic. Nice car too!

 

[shed or dead]

Hi, The finished item should have similar curves to this one.

http://www.classic-kitcars.com/81/646/646picgallery.htm

The buck was just to establish where the curve would begin, and hold up the blank while i wrestled some measurements out of it.

Thanks

 

[Exuptoy]

Ooooh, that will look nice then. Understand where you're coming from now.

 

[shed or dead]

Been working in the living room but took it out to the garage to do some sizing up.

 

[wildcat]

Looks like it's coming along nicely.

 

[Ben Caswell]

Hi James and Gav, The hard top project looks interesting look forward to seeing it finished.

My interest is in your Marlins as on behalf of the Marlin Owners Club I hold the Mk1 register and would like to ask for some more info on both your cars. ie: the reg number and chassis number. Also I am the Triumph tech advisor so if you need any help I will do my best to answer any questions.
If this is OK please email me b.caswell@virgin.net or PM me here.
Much obliged
Ben Caswell