Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 (edited) Back to it then? Hope you all had a great bank holiday weekend not that you could get out much given the current situation, this did mean that I "had" to stay home and as Mrs K was busy painting the hall as the painters couldn't come and I would only be in her way in the house I thought it best if I found something to do in the Zed Shed Been busy all weekend on The Bug, it’s amazing how quickly time flies by when you are fabricating things, if time was being billed this would not be worthwhile but I really enjoy this stuff and I have the tools and space so why the hell not Before I crack on with the rebuild there are several issues I need to address, and I’m waiting for a load of parts to arrive which may be slower than usual again due to the current lockdown. Anyway, the first thing I decided to tackle is this – The Dash! So, what’s wrong with it? - Well it would be quicker to list the things that are right with it, 1. Nothing Problems. 1. The speedo which has all the warning lights incorporated in it is not in line of sight. 2. It is not waterproof or even splash proof as you can see above it has no base. 3. The buttons (pic below) especially the indicator switch are useless while just testing the indicators I can’t turn them off which is a half press a complete press is about 1.5cm imagine trying to do it while driving! 4. The heater gauge which for some reason is bigger than the speedo is mounted behind the dash on the frame – I have no idea maybe they added it later? 5. There is no fog light switch – but then there is no fog light. We need one though. 6. Its plastic and looks cheap Apart from the horn button which is OK I have nothing good to say about it. My solution was to get back to my Blue Peter fabrication technique – Starting with a cardboard template that puts all the switches in a row, separates the indicators, incorporates the temp gauge and puts the speedo where it should be in front of the driver! Find a big enough scrap of aluminium And cut out the basic shape, Now the fun, go through a plethora of hole cutting bits to get the right size for eacj switch and/or dial Bit of help from the DRO on the mill to get 30mm centres in a straight line @andybp before you say anything 0.022mm is within my tolerances That got me to here and that will fit here something like this – Front Back I made this up as I went along so I now had to work out what to do next ………………………. More in a mo……………………… Edited April 14, 2020 by Keyser 2 Quote Link to comment Share on other sites More sharing options...
ATTAK Z Posted April 14, 2020 Share Posted April 14, 2020 Design reminds me of the E-Type Jag dash 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 Before I worry about minor things like how to make it stay in place I thought I’d improve the temp gauge angle – Que the montage – That’s better Now then the ends of the dash – Hmmm Ahhh I know Bit of aluminium pipe cut down and cleaned up Cut that in half Weld those on the ends and it looks like this Next I removed the original das mounting tags Cleaned the metal up and noticed the bar is threaded = idea for mounting Some aluminium angle Cut and drilled Tack weld that on Rinse and repeat for the other side Some tatty scrap from the bottom of the pile Cut and cleaned up to make the fill in bits Onto the welding (self taught ally TiG welder here don’t expect YouTube welding tutorial levels of quality) But it sticks together so not all bad Then the welder broke (OK I drooped it – it was hot!) Stop laughing ya bastards I knew it was hot I just lent in the wrong place – I have the scar and everything!!! Anyway, I keep spares for the welder so that didn’t slow me down for long! The burn did – I cried like a little girl Still more coming …………. 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 Moving swiftly on then, Made a couple of mounting brackets for the gauges Welded those in Onto the top I angled the edges so I can go for an invisible weld Here goes again (Try not to burn myself this time ) Clamped Spot welded Welded Sanded I like it so time for a test fit Tomorrow the back and cable entry fabrication Stay Safe Keyser - " I don't want to be alone; I want to be left alone.” - Audrey Hepburn (and she didn’t have a Zed Shed ) 6 Quote Link to comment Share on other sites More sharing options...
andybp Posted April 14, 2020 Share Posted April 14, 2020 6 hours ago, Keyser said: 0.022mm just some of us have higher tolerances than others some of us have a clunky agricultural mill others have a higher precision CNC machine some of us are more equal than others sorry Chris couldn't resist 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted April 14, 2020 Share Posted April 14, 2020 Great work Chris I always love to see this level of fabrication sadly the only thing I've been doing is undoing all of my hard work and putting my Z back to stock (ish) prior to selling it 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 46 minutes ago, andybp said: back to stock (ish) prior to selling it No why you selling 56 minutes ago, andybp said: some of us are more equal than others Yes some of us are 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted April 14, 2020 Share Posted April 14, 2020 13 minutes ago, Keyser said: No why you selling Yes some of us are yes I'll give you that truly awesome bit of kit selling because I don't have the time or the room to play with it so i'm selling to get a more practical car (z4 35i dct) until we move and I retire 6 yrs then I'll have the time and space for a toy again 1 Quote Link to comment Share on other sites More sharing options...
andy james Posted April 14, 2020 Share Posted April 14, 2020 Awesome skills as ever Chris. Hows the Boss getting on with the painting?...... 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 2 hours ago, andy james said: Hows the Boss getting on with the painting?...... Don't ask she got more paint today 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 Well I have an hour to kill so I thought I’d post up some more on the dash build, Firstly I removed these original mounting tabs and the temp gauge holder All gone Now this is all the wiring that needs to go “neatly” (read hidden) to the back of the dash So some more bits I had laying around I milled 6mm of one edge (the side wall is 3mm) see if your ahead of me Spot weld Big weld Sanded back Lined it up on the frame and spot welded it in place Ugly weld So, I checked the dials on the TiG I came to the conclusion there are a lot and I have no idea what most of them do Back on the bench 2 more of the same angle bits and a piece of card (to allow for powder coat_ Now you know why I milled 6mm of it All welded up More coming ……………………………. 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 14, 2020 Author Share Posted April 14, 2020 (edited) The final instalment in the dash build Well done if you stuck with it, 2 days went into this, It was fun to be fair and what else are you goanna do on Easter weekend while on lockdown? Another template Transfer to ally Test fit Mark the deliberate mistake in red – I used the front template again and forgot about the overhang at the front Now it fits So cut a rough hole in it Then mill it all up square To give Make a back mark it out then drill it Tap some threads into the back plate Clamp it all together Must have got one of those dials in the right place my welding isn’t as ugly Extra clamps to keep it all square All sanded back Drill a hole in the cable box Add grommet Finish the lid The finished article ………………………. And on The Bug Hope you enjoyed that, tomorrow we move onto extreme cleaning Be Safe! Keyser - It is far better to be alone, than to be in bad company. George Washington – I’m definitely a bad influence not sure about company Edited April 14, 2020 by Keyser 7 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 15, 2020 Author Share Posted April 15, 2020 Hope you are all well rested and ready for the next exciting (or not) episode in a Bugs Life! I have a few thigs to do on The Bug to get it up to MOT standard, Beb and I agreed that we wouldn’t mod it, which we both knew meant we will do anything we want to it I don’t think we have any unmodified projects between us! I also get carried away doing these things, it is basically my hobby to spend weekends when I’m not out in cars either at meets or on track to play with them in the Zed Shed. Mrs Keyser sews and makes clothes and handbags for fun I engineer (I use the term loosely). This brings us on to a clean up, the wiring needs a few repairs like the lights shown in an earlier post, I’m rewiring the dash and it needs a clean so I thought I’d take that out to start. This is the battery box as you can see this vehicle needs a serious detail The brake lines looked dirty, so they came out The gear stick needs a good clean and maybe some paint Yup, that’s out as well Now cleaning the engine is awkward, so…………………… That came out – I’m so glad I fitted an overhead winch, it makes working on your own so much easier That left The Bug a bit bare Now I can see it all I realise that a lot of the body work needs attention I know a lot of forum users are mad about detailing but I don’t use the 2 bucket, 6 sponges and loads of chemicals and wax I don’t even start with a clay bar I prefer the 1 container approach for the really dirty metalwork – and I fill that container with crushed glass 1 hour in 4 hours in 6 hours in At this point 3 things became apparent 1. This is a PITA to blast as you can’t get behind a lot of the frame! You can’t even get to it from underneath due to the undertray. 2. This will be a complete pig to respray for the same reason. 3. The front offside lower wishbone mounts are all badly bent, they will need some serious attention but the undertray covers the point they weld to the frame. Nothing else for it the undertray must go – out with the angle grinder. Access granted - You can see the rust I couldn't clean as well. The afore mentioned wishbone mounts More on those and the repairs to come in another post. After another day in the blast chamber I had the frame “clean” and ready for the repairs to start I’m getting a couple of hours a day in so hopefully this will keep progressing, the parts I ordered are starting to trickle in and there seems to be more than enough to keep me going until the rest of them arrive – I’ll keep you posted. Be Safe! Keyser - Being alone makes it harder to find someone to blame. Mason Cooley (So true Mason) 4 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted April 15, 2020 Share Posted April 15, 2020 The size and flexibility of your equipment is very impressive, very jealous. 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted April 16, 2020 Share Posted April 16, 2020 18 hours ago, SuperStu said: The size and flexibility of your equipment is very impressive, very jealous. Is it just me or is that a double entendre 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 16, 2020 Author Share Posted April 16, 2020 20 minutes ago, andybp said: Is it just me or is that a double entendre I'm not sure but the women don't seem so impressed 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 16, 2020 Author Share Posted April 16, 2020 Morning, morning, morning Another quick update to help pass a few more minutes of your day as you sit there wistfully staring out of the window at your pride and joy hoping the weather holds after the lockdown and you can actually go for a drive. First repair This is a genuine non modification repair, I mentioned in a previous post that I spotted that the lower wishbone brackets/mounts were damaged, my diagnosis is that they had a fairly heavy bang on the wheel and it bent the wishbone and the mounts, this explains why all the other 3 wheel mountings are black and this one is silver. So I assume they bent that beyond repair and replaced it, however they damaged the hangers This is the good side This is the damaged side I think they put the new wishbone in then basically beat the bolts and hangers with a hammer until it fit This has in turn lead to further damage as the extra pressure of not being straight has elongated the holes, as you can see after I cut the bent bits off So the challenge was to make some replacement hangers and reset them in exactly the right place – I Love A Challenge I immediately ran to my PC and produced a full CAD design of the part; cross referenced the materials used with the steel stress and tolerance guide. I then transferred the design to my CNC programme, loaded it into my precision CNC machine and set it to produce the required parts. No stop wait I was confused for a moment its @andybp that has the precision CNC machine, O well lets see if I can produce anything worthwhile using only my old “agricultural” milling machine a welder and a 4” angle grinder shall we??!?? Here goes – I started by taking measurement (I did use a micrometre) then produced my version of a technical drawing Materials were as always selected from my steel pile as having about the correct dimensions, in this case an offcut of box as the side walls were thick enough Cut that in half the “other way” Cut a curve in one end To give Test fit Happy with that make 3 more (I wanted a spare) A hole is needed – the micrometre says 40mm from the inside of the curve at the closest point Set a reference point and came in 40mm Then it has to be in the middle – 30mm bar so 15mm to centre Ha hows that for tolerance (it took about 5 mins to get that and it still moved .002mm when I tightened the stops – I only did it for you Andy!) I have issues – anyway moving on, a hole was drilled Now for some chamfering I set a guide inside the vice (you can’t see it) but that gave me the correct angle to mill the parts. So now we have Now this is just because I wanted to try and replicate the original part I ran a line of weld across the top of each bracket Milled that Then cut them to length and sanded them off to give the finished article Next to the damaged part Next up – alignment and fitting Stay Safe!!! Keyser - Remember we're all in this alone. Lily Tomlin 7 Quote Link to comment Share on other sites More sharing options...
Beb Posted April 16, 2020 Share Posted April 16, 2020 Haven't sent you any abuse for a while but this build is so good I'd almost feel bad. Didn't realise it would take 6 hours to sandblast and that attention to detail with the lip around the bracket, knowing no one will ever realise the amount of effort 2 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted April 16, 2020 Share Posted April 16, 2020 Given the whack it has taken, and the abuse I imagine you'll be giving it in future, any plans for a couple of structural inserts? 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 16, 2020 Author Share Posted April 16, 2020 43 minutes ago, Beb said: Didn't realise it would take 6 hours to sandblast Read it again - 6 hours first day and "another day in the blast chamber" so 14 hours and that was just the main frame But I'm having all the fun on this project Get back to licking your batteries Cheers for the support - I do like comments 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 16, 2020 Author Share Posted April 16, 2020 28 minutes ago, SuperStu said: Given the whack it has taken, and the abuse I imagine you'll be giving it in future, any planes for a couple of structural inserts? I'ts like anything I could make it stronger but weight is an issue it is only the 250cc version and I'm adding some "saftey" features and therfore weight already! The plan really is to do it up, pass the MOT give it some "light" abuse for a while then sell it on and @Beb and I have plans on getting the bigger version - I say plans we just do random projects and Beb is a master at finding wierd "bargains" Mrs K hates him for that as he keeps making me spend money - but she loves the fact I'm out of her way and in the Zed Shed so it's swings and round abouts , she also likes to feed so when Beb is here she try's to fatten him up - think Christmas turkey Keep the comment coming 1 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted April 16, 2020 Share Posted April 16, 2020 Seems like the power to weight problem could be solved with a V8, no? 1 Quote Link to comment Share on other sites More sharing options...
veeg33 Posted April 16, 2020 Share Posted April 16, 2020 Keep it coming! I really think you should have a crew filming you all the way. Keeping up with Keyser (keeping up with the Kardarshians ) 1 Quote Link to comment Share on other sites More sharing options...
ilogikal1 Posted April 16, 2020 Share Posted April 16, 2020 Pitch it to Netflix. Netflix will make anything, so this would be better than at least 60% of the content! 1 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted April 16, 2020 Share Posted April 16, 2020 Chris I detect a small amount of sarcasm in some of your comments please note that this is my area of expertise (just ask the poor souls i work with) so please cease and desist just stick with what you are good at eating donuts and taking blurry pictures Excellent work by the way do love some of the solutions you come up with we should have done scrapheap challenge you could have done all the work and I could look good for the camera Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.