FOM The Clubman Estate

[Tupers]

I made a start on the exhaust flange for the supercharger with some 6MM plate.

Then I made a template of the inside of the flange and laid it over the blank.

I tried using the plasma cutter but it wan't up to 6MM steel so I resorted to a hole saw and grinder, still lots to go.

Everyone was getting a bit bored of me being noisy I turned my attention to the top dash rail.

The original had studs for mounting but I needed to changes it over to captive nut so I made a couple new brackets and got them welded on.

I'm still swinging between a 2 or 3 gauge dash but decided to go ahed with the 3 and see where it goes. I started by making another gauge hoop and mounting it up with the other 2 I'd already made.

I'm quite happy with the distance the gauges come out from the dash but I think I'm going to move them up by one more inch.

I'm thinking the final product will look something like the top drawing but with 3 gauges instead of 2.

 

[Tupers]

And now more pictures to illustrate how I can spend an entire morning doing not an awful lot.

I thought I'd give the plasma cutter a chance to redeem its self and used it to cut out a plate to mount the gauge hoops to.

Got a bit of a rough cut as the tip needs replacing so I cleaned the edge up with a pair of aviation snips.

After a little fettling I got the hoop to sit where I wanted them and got them welded in a tidied up.

They all sit in rather nicely, now I need to figure out how to make everything else.

 

[Tupers]

Not really a proper up date in fact this is a bit a jump backwards.

After getting the back end up on stands to have a look at how to route the exhaust I decided to cuts out the whole tank/battery box assembly and start again. To get the original system to work I would have needed to notch into the already small tank box so I'm just going to make new bigger one and position it better.
Before:

After:

Instead of running from side to side the new box will run length ways and should actually clear the exhaust.


In brighter news we got a new MIG welder and I thought I'd put it to work making an stand for our spare vice.

And I got a nice leather shot bag, now I just need to figure out where I can get cheap lead shot.

 

[Robotstar5]

And I got a nice leather shot bag, now I just need to figure out where I can get cheap lead shot.

Local clay pigeon range - need a lot of patience and a pair of tweezers

 

[octo0072000]

Try a Dive shop they use it for shot weight belts

here we are lead shot just type lead shot in to ebay

http://www.ebay.co.uk/itm/LEAD-SHOT-WEIGHT-BELT-SCUBA-DIVING-3KG-/160477178464

 

[Fergus]

And I got a nice leather shot bag, now I just need to figure out where I can get cheap lead shot.

Gunshops are worth trying, but unlikely to be cheap. I'd be interested to know what you turn up with Dive shops.

One day I'll make up the shot dripper I keep threatening to make.

Incidentally, before you fill that bag give it a good look over, the one I got had a defect in the leather and tore like paper when filled. It was replaced without any hassles, but that shot gets everywhere.

 

[Tupers]

I've got a friend who shoots so I'm going to see if he can sort me out with some lead. I'm trying to avoid filling the bag with sand at the moment as the filling hole in it is tiny and I'll never get out out again if I don't like it.

Back onto chopping large chunks of steel from my car. I realised the rear floor was just going to end up looking like patch work quilt so it's all coming out and I going to start afresh.

I got most of the floor out from behind the subframe and tomorrow I should be able to pull the rest out and start making patterns for the new floor.

I thought I should probably add a bit of structure before I go too far so I got the window frame/seat mounts welded in. It's amazing how much the stiffen the back end up.

The new rear step sill arrived from M-Machine in record time. It's a very nice pressing so I'm sure it should go in without too much trouble.

 

[Springerdinger]

Hi Tupers

For the bag filling try a local aquatics (fish shop) and ask about the sand that they use in the fish tanks.
Silver sand or kiddies play sand, also sugar fine arragonite sand will all pour in through a small funnel/ small hole. I used it in my shooting bags. Much cheaper than lead

Hope this helps

 

[brightspark]

Hi Tupers

For the bag filling try a local aquatics (fish shop) and ask about the sand that they use in the fish tanks.
Silver sand or kiddies play sand, also sugar fine arragonite sand will all pour in through a small funnel/ small hole. I used it in my shooting bags. Much cheaper than lead

Hope this helps

kiln dried is on par with silver sand /

 

[Angusdog]

I thought I should probably add a bit of structure before I go too far so I got the window frame/seat mounts welded in. It's amazing how much the stiffen the back end up.

There's not much meat at all in an estate, which is why mine is ending up a two seater - there's nothing to attach seat belts to so we could never carry the kids. Yours looks very much stronger than standard. As always, lovely work.

 

[Tupers]

There's not much meat at all in an estate, which is why mine is ending up a two seater - there's nothing to attach seat belts to so we could never carry the kids. Yours looks very much stronger than standard. As always, lovely work.

Thanks you.


After chopping out the majority of the boot floor I was still left with the corner sections to remove.

A bit of tactical drilling and dring saw then gone ready to for new ones to be made.

There was a little section of the lower C post that need some attention so I tackled this before moving any further.

With the C pillar sorted I was able to move along with the step sill. It took a couple attempts to get it centred but the fit is really nice.

I replaced the panel clamps with a few self tappers on each side until I'm ready to weld the sill in.

Now that the sill was in I moved back to the corner section of the floor/sill.

And finally my brothers MG metro race car that he finished off last night to race at Silverstone on sunday.

 

[Tupers]

I got bored of watching the F1 after about 5 laps this morning so I thought I'd go down to work and finish up the rear sill.

Before I put the sill on I added a small tag to each side that would slip into the door frame and get plug welded in place to add a little more strength.

It all went together fairly painlessly bar the moment where I burt my self while plug welding upside down.

Once I get round to body work I'm going to braze this joint as it'd be a pain in the **** to try and MIG it up and then grind smooth.

I also had some shinny bits arrive, namely 3 jetex tight 90 bends for the exhaust and a thermostat housing from a 1275 MG Midget.

The stat housing will point backward and feed into a swirl pot (illustrated by the Rock Star can) which will have an exit at the bottom feeding into the top of the radiator.

This is my first thought for the exhaust system. The first two bends will be cut so they're closer to 70 degrees and I may replace the last on with a mandrel bent piece.

 

[Tupers]

I did a bit of work on cleaning up the rather grubby rear cross member this afternoon. A few minutes with a knotted wire wheel on the grinder and a lick of zinc primer saw it turn from this:

To this:

I also added a small closing plate at each end of the cross member to keep the subframe fixing plates shielded from any grime that works its way in.

 

[Tupers]

Well the whole boot floor's out now.

The turret tops came off as well to sort out some rust that was hiding underneath them.

While I was at it I made up a profile template for the centre section of the new floor. The new tank should take somewhere in the region of 6 imperial gallons.

 

[Tupers]

Another quite Sunday so I thought I'd go and fold up the centre section of the new tank box/boot floor.
After going over my scrawlings again I figured out I could make the tank a bit wider meaning it will be closer to 6.5 gallons.

This has got to be the most awkward thing I've folded so far.

It fit's like a glove, just need to make the other sections now.

 

[the snooper]

with all these mods, will you still be of an age to drive it when its actually finished

 

[Tupers]

I'm only 21 now so I think I should be OK.

 

[the snooper]

are you putting anything on the new floor to stiffen it up, as it will probably make a right noise at certain speeds

 

[Tiggy_dorset]

It'll be like painting the Forth Bridge, once finished he will have to start all over repairing his work which has rusted through from rotting with age

 

[Angusdog]

Harsh! He's making much faster progress with his than I am with mine!

What about rolling a bead into the floor? That plus sound-deadening panels like Dynamat will probably be enough.