Project #2...Nissan Figaro

[Pigeon_Droppings2]

I think I'm just going to make them in 2 halves....much easier. Don't think they are symmetrical as the online suppliers sell them as sided.I'm going to start by just making a very think arch to get in some practice (1 inch maybe). If that works then I'll try something a little more ambitious....I should be able to use the practice efforts to patch the inner arch so they won't go to waste :-).

£199 for a pair of arches seems insane to me....especially when the panel is this simple! I think the front part of the wheel arch is the easier part....the rear has all sorts of funky curves in it. Could I just weld in a 1 inch repair arch with the flange and then patch up to it....or is that a stupid idea?

 

[Pigeon_Droppings2]

Spent a few hours today getting my stretcher mounted up and sorting out a sheet cutter that I've owned for years but never used.

Had a play with a piece of scrap....I have to say this stretcher tool is amazing. Wish I could have afforded the larger model but hey can't have everything. Literally took me 2 minutes to do this....wish I had this when I restored my MR2!!

 

[slim_boy_fat]

And as a bonus, that's another skill learned!!

 

[Pigeon_Droppings2]

Yea quite a nice feeling actually....that was literally my first attempt so will take some time to master. I'm going to attempt the double ply former next and see how that works out...been a bit busy with other stuff today so not as much time in the garage as I'd like!

On the up side my house renovations are finally over

 

[Pigeon_Droppings2]

Today I worked on the template for the wheel arch (trying the template approach next). Started by making a cardboard template of the passenger arch on Chung Lee...I then flipped it around and check it also matched the drivers arch which it did perfectly. Next I cut 2 ply templates on the band saw....would have used the jig saw but no idea where the blades have gone! I then clamped up a piece of scrap and knocked it into a wheel arch....it worked perfectly! Ideally I would have used a thicker sheet of ply....but this is all I had in the scrap pile.

I think this approach is actually easier than using the stretcher as it's alot easier just hitting the metal around a former than trying to gauge the shrinker and keeping things symmetrical.

Sorry about the funky socks...

 

[Pigeon_Droppings2]

The existing arch has been badly patched...it was only tacked in a couple of places so I figured I would cut the tacks and fold it back...hoping that it was just the lip that has rusted out.

No such luck...I suspect this rust has actually been encouraged by the patch....that square of rust lines up perfectly with that square patch!!

If you look closely in the second picture you can see the original rust hole and also the big lump of filler that was pushed in from behind to cover up the hole in the inner arch....pretty sure these patches should have been continuously welded for the MOT so this is indeed a botch!

 

[Pigeon_Droppings2]

This is how the arch looks when offered up (after removing the rubbish patch repair). I must say I'm pretty happy as I was able to clamp it to the existing lip and it sits quite nicely. This is just the rough shape...I intend to fettle the shape and also add the lip feature but that can wait...I left the sheet uncut as I would also like to form the repair to the lower rear quarter using a single arch piece but I don't actually know yet how big that needs to be so easier to just put it to one side and come back to it when I'm ready.

 

[Pigeon_Droppings2]

Was one of those days when I get left alone and can get on with stuff. Decided to take a look at the sills...first I welded in a brace bar though...with this car having a soft top I'm not convinced how rigid it actually is...

 

[Pigeon_Droppings2]

Finally some cutting....I've told myself this is just deeper investigation work...in practice I just can't wait any longer.

It looks like water has been getting into the sills and they've rotted from the inside out. Strange...that inner brace structure has plenty of holes in it....you'd think they might have put a few drain holes in the underneath too!

I stuck my finger into the holes....it feels like they are full of road dirt...I suspect coming down the roof drain. I think I'll need to cut the bottom off that inner structure and put some new steel in there too.

I'm a little worried about cutting out too much structure though....I know the inner sill and floor will also need work....is that more easily done from the outside or better to work from the inside? Also how much of this can I reasonably cut out and still keep the shell from moving? The front of the car is in the air so I'm thinking most of the weight is actually on the front suspension...but to be honest I'm a bit unsure....even with the brace bar!

 

[Ton-up]

Your doing a great job, you sound like you are enjoying it!

As you say more braces would be good for piece of mind. Normally see people put braces at top of doors as well and then diagonal. Also put diagonal from A pillar bottoms to opposite B pillars and one across tops of B pillars.

 

[Pigeon_Droppings2]

Cheers Ton-up...I think I will put a bit more bracing in there. It's not so much the brace itself but it ties into fairly thin steel on the pillars so agree a few more points of support would be good. The Figaro is a fairly light car though....810Kg I think. I've probably removed around 100Kg with the interior and roof, the suspension and engine/box are around 200Kg I reckon but they are pretty much directly over the wheels. I think that leaves around 500Kg trying to move the door opening....so maybe 250Kg per side acting in tension/compression etc. I was thinking it might be easier to just brace between the front and back suspension points as it's easier to tie into a more substantial piece of the structure...has anyone done that instead of bracing the doors?

I'm leaving the door on too for some added support.

 

[slim_boy_fat]

Cheers Ton-up...I think I will put a bit more bracing in there. It's not so much the brace itself but it ties into fairly thin steel on the pillars so agree a few more points of support would be good. The Figaro is a fairly light car though....810Kg I think. I've probably removed around 100Kg with the interior and roof, the suspension and engine/box are around 200Kg I reckon but they are pretty much directly over the wheels. I think that leaves around 500Kg trying to move the door opening....so maybe 250Kg per side acting in tension/compression etc. I was thinking it might be easier to just brace between the front and back suspension points as it's easier to tie into a more substantial piece of the structure...has anyone done that instead of bracing the doors?

I'm leaving the door on too for some added support.

Think of a shoe-box with the lid removed, it's easier to twist at the end corners [long sides] than at the middle. Not very well described.....

 

[Pigeon_Droppings2]

Cheers Slim....that does make sense actually. So if it twists you'd see the door gaps at opposite corners either getting smaller or larger.

Having had a think I decided to drop the car back onto the ground and take some measurements. The logic goes...if there are any twisting issues already then I need to be aware of these before I put a load of bracing into the shell and fix everything in place!!

 

[Pigeon_Droppings2]

While thinking about the bracing I decided to attack that door again. I worked out (after ignoring "someones" suggestion about a week earlier!!" a little heat from a paint stripper gun softens the filler enough to get the scraper behind it. It still took an age to get it all off...SHMBO also helped with the air gun (after reminding me whose idea it was!) and also getting the door glass out.. .in one piece!!

Can't believe there is another pile of filler!!

 

[Pigeon_Droppings2]

I still have no idea why it was so full of filler...there is a patch of rust at the bottom of the doors but otherwise looks kind of ok to me. Also the door gaps in this side look ok to me so need to keep them looking that way!! I can see two patches so am sure there is some fun to be had there as I'll need to cut them out and redo them properly!!

 

[Pigeon_Droppings2]

You could be right....it literally seems they coated the entire car in the stuff. At the top of the door they put in so much that they lost some of the curve. Crazy crazy...I was expecting to find a big dent in the door somewhere....anything to give some logic to what was done but nop!!

 

[Pigeon_Droppings2]

Lastly I started setting up some levels so I can monitor where things are while I work on the sills. Still a work in progress....I need some adjustable stands I think....has anyone got a set of those caravan ones....the ones with the screw thread. Do they work ok...ish. The Figaro is a very light car....I'm thinking of using ramps at the front and stands at the rear to get it off the ground??

 

[Pigeon_Droppings2]

In case anyone is wondering it's a nice Italian red....I think it would also work with a French red but wouldn't be as enjoyable to make in my opinion!!

It looks easy but there is a knack to getting the tube filled with wine and no bubbles.....after a couple of tries I worked out the easiest approach was the most obvious....take a glass of wine and fill the tube from my mouth!

 

[slim_boy_fat]

.....after a couple of tries I worked out the easiest approach was the most obvious....take a glass of wine and fill the tube from my mouth!

Having swallowed some for purely 'quality control' purposes, of course.

 

[rtbcomp]

....I need some adjustable stands I think....has anyone got a set of those caravan ones....the ones with the screw thread.

Try & get some scissors jacks, I'm sure a scrapyard would let you have them for next to nothing.