andybp Posted April 21, 2020 Share Posted April 21, 2020 Definitely going to have to upgrade the engine that things gonna weigh a ton Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 21, 2020 Author Share Posted April 21, 2020 1 hour ago, Beb said: Definitely not going for a full sheet undertray.... 2 mins later... armour plating. WTF did Kim put in your coffee you can’t blame Kim it’s your fault, where were you when sane rational advice was needed Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 21, 2020 Author Share Posted April 21, 2020 1 hour ago, andybp said: Definitely going to have to upgrade the engine that things gonna weigh a ton Well the old undertray was heavy weight steel so it’s only a small weight gain and it adds some safety not to mention we can bounce it off rocks without worrying to much the next one will have a bigger engine though Quote Link to comment Share on other sites More sharing options...
Ebized Posted April 21, 2020 Share Posted April 21, 2020 9 hours ago, SuperStu said: I know we're somewhat prone to taking the p!ss but I just wanted to say, in all seriousness, this is the absolute high point of my days right now and love following whatever dangerous and interesting new pursuit you've turned your hand to. I'm pretty sure we (notice I said WE, because I'm so involved!) are building a boat now, but if not, it must be an aeroplane, either way - thanks so much for taking the time out from doing the actual work, to take snaps and write it up and share it - it's AMAZING. Agreed, although the boat idea made me think that they are designed to float, so was wondering with our typical English weather, if there will be enough drainage holes in this boat so it doesn't turn into a water play tub 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 22, 2020 Author Share Posted April 22, 2020 Looking out of the window it looks like another fine day, my work diary has 1 job in it so I’ll be out in the garage this afternoon again, I did about 6 hours yesterday I only had 1 call out and about 3 calls all day – it is ridiculously quiet at the moment! On the plus side I did 6 hours in the Zed Shed yesterday Another long post today but we are still on the floor plan, I did say it would be a major undertaking to try and do this…………………. I took the undertray off to carry on with the trimming and shaping, the first job was to trim the front edge to length now I had decided how it was going to fit That line you can see about 4cm back from the front is where I got 2/3 of the way through the cut when I realised I was cutting the wrong line so I had to weld that back up again – what a muppet! Anyway did some more stich welding Its really taking shape now I cut out 2 holes in the base – I’ll come back to those later in the project when I have a whinge about a design feature. I also made a decision to make the complete floor pan removable, this is mostly due to paint, there is no way I can get good coverage on the underside of the frame work around the front end with the undertray on. My original idea was to spray the underside then weld the floor pan in and paint again, but that means welding onto painted sections or paint grind and repaint and whichever way it goes I will have badly covered areas, as this is both roofless and designed to get muddy off roading good coverage is a must! It also means maintenance is easier although I can’t see many reasons to remove the floor pan for general maintenance, but I’m on my own and that’s what I decided after discussing options with me So to facilitate the removability (big words) I tweaked the slots And then drilled some holes and used my “too long” bolts – new stainless shorter bolts are on order – Bit more massaging of the armour plate with a hammer and the sides are getting close Onto the back corners No choice other than to cut and shut this - no amount of beating with a hammer will shrink that much metal down and I don’t have a 1000 ton press so More on it’s way ……………………………… 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 22, 2020 Author Share Posted April 22, 2020 I found the use of a G-clamp helped hold the shape ready for a quick weld Getting there First weld on Then onto the other side same thing again Back to the bench for the stich up and sand Back on the frame to test the fit The inside looks great And a delivery of sanding disks arrived (I buy in bulk to save money) That’s as far as I am going with the floor pan at the moment, I want to look at the next part of the project before I fine tune the back edge. I have just had a call out for a server fail so there may or may not be another post today – I’m actually going to work for a while Be Safe All!! Keyser - “I don't want to be alone, I want to be left alone.” ― Audrey Hepburn 3 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted April 22, 2020 Share Posted April 22, 2020 Nice job, flat floor should help with aero and add a touch of negative lift. 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 22, 2020 Author Share Posted April 22, 2020 (edited) 2 hours ago, SuperStu said: Nice job, flat floor should help with aero and add a touch of negative lift. I wish I think this does 50mph downhill with a strong tail wind - but we live in hope Just got back from my call out - It was an emergency call out so I took the fast response vechile Please note my new number plate - People always as Is that the V10? and I say YUP I really need to get a life But a PC fits in so completley justified me driving her today Have a good one guys n gals Keyser Edited April 22, 2020 by Keyser 5 2 Quote Link to comment Share on other sites More sharing options...
HEADPHONES Posted April 22, 2020 Share Posted April 22, 2020 If MacGyver or The A-Team ever needed a base....... it'd be The Zed Shed. Mad skills at work there Quote Link to comment Share on other sites More sharing options...
Beb Posted April 22, 2020 Share Posted April 22, 2020 21 hours ago, Keyser said: you can’t blame Kim it’s your fault, where were you when sane rational advice was needed Sane and rational advice of course. I was gonna suggest kevlar but that's much better, esp when it's from the little scrap pile! Liking the new plate Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 22, 2020 Author Share Posted April 22, 2020 No progress on The Bug today...................actual work squashed my plans I did however have a couple of hours this afternoon available before other commitments with daughter No 2. I thought, rather than start on the next bit of the bug, I’d get a couple of side projects moved along a bit. Side Project 1 One of our more senior members spotted that there maybe some off cuts of that 3mm steel and as the eco-friendly guy he is he would feel remise if he did not suggest they be repurposed for a small project of his own, after all this would be much better than them going to the scrap yard After a brief email chat (he sent me the spec) I thought I’d see if I could make up some bits that would let him finish his current project. First requirement was 4 x 14cm disks in 3mm steel So the two bits from the rear corners of the floor pan were pulled from the scraps bin and marked up Quick rough trim And a hole in the middle Bolt them all together And a spin in the lathe to achieve circularity Requirement 2 Chamfered edge to avoid scraping Back in the lathe one at a time To change the edge from this To this Requirement 3 Counter sunk screw holes to mount them with, now I figured if the edges were chamfered to stop scarping the screws would need to be flush or lower than the surface of the discs, this is not that easy with only 3mm to play with, so some test countersinks were done When I had it just right I set the bump stop on the Mill (I Use it as a drill press as well ) The resultant counter sink gives flushness But after drilling they look like this A quick clean up and degrease Requirement 4 – There was no requirement 4 so I took it upon myself to go one step further A quick trip through the powder coat oven And I added a fitting kit I’ll get them in the post for you tomorrow mate I would like to dedicate this post to my recently departed angle grinder as it spun it’s last today ☹ Probably the hammering I gave it on all my bad welding Don’t worry I keep spares Be Safe Keyser 4 1 Quote Link to comment Share on other sites More sharing options...
Ebized Posted April 22, 2020 Share Posted April 22, 2020 You are a star mate after my cheeky ask. Thank you so much. For anyone wondering, not car related at all - but new soles for the legs of the garden table that had seen better days. 2 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 23, 2020 Author Share Posted April 23, 2020 Another day another dollar as they say, or in this case another post. This is not only another big post, well multiple posts as it is hard to keep track of the pictures after 10 – I run out of fingers this is in fact a complete waste of time!! But as you lot have stayed with the build so far I thought it only fair that you had a blow by blow account of the failures as well, I’m not perfect and these modifications are not some bolt on part with instructions and maybe a bit of fiddling to get them to fit. Each part comes from the depths of my mind – that’s a bad place top start and are then built from scratch, and as much as I really appreciate the complements on my work, the pedestal some of you have put me on is completely unjustified cause I can **** it up with the best of them That’s were the famous saying “something will happen” comes from as both @Beb and I are willing to try, the result may be good bad or anywhere in the middle. So please join me in one that I deemed a total failure……….. The plan is to make quarter panels to again reduce the mud splash, protect the seats and ultimately allow me to link them into a firewall as these don’t have one out of the factory – I say factory I think it’s a garden shed somewhere Starting with some good old card To make a template Transfer to metal The lovely shape was gained using a knee, a hammer and a dolly – meet dolly Gets this sort of thing Then I marked it out for some bead roller action – that’s this thing, I added a motor to it ages ago so it’s a one-man operation Marked out for said roller No pic of it rolled That was then welded into the frame I know you are most likely thinking that it looks s**t – I know I was!! The weld is bad – I’ll explain that in a moment – and it’s not a uniform curve, this is because the top frame rail and the one below it are both a different diameter and a different radius, I can do very basic panel beating but this needs the art of shrinking and stretching, a lot of it and I’m not that good, if these were mass produced they would be done in a HUGE 1000 ton plus preformed press, but I couldn’t find one cheap on eBay so after many hours trying to make it look good I gave up and ripped it out I thought I know if I put a separating bar in the corner and make 2 panels it will look much better Apparently, I couldn’t have been more wrong that looks worse than the first attempt!! The welding is ugly because I’m using 0.9mm steel so it is light which is fine, the issue comes from welding it to the heavy frame at the edges, I have 2 Mig welders my favourite This is my 3 phase Esab and it is an amazing welder, I acquired it cheap from a cattle grid fabrication factory that was shutting down, The fact that it is 3 phase leaves a very small customer base and keeps the price down, but as I have 3 phase I win Then I have my Hobby welder This is your average £150 Mig welder it is a SuperMig 130 (nothing super about it) it is OK……. just. Now the Esab runs .08 to 1mm wire and the heat it generates to melt the wire literally melts the thin metal before you can run a weld, the 130 runs .6mm wire which is about right for 1mm steel, the problem is getting it to run hot enough to achieve penetration on the thicker frame steel. Well that’s my excuse, you could also argue a bad workman blames his tools so I’ll let you decide if its me or not Anyway back to attempt 2 Yup that got cut out and binned as well! I told you it was a waste of time. More coming …………………………………………….. 2 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted April 23, 2020 Share Posted April 23, 2020 First firewall looked fine, just needed a bit of filler, some sanding and a splash of colour 1 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 23, 2020 Author Share Posted April 23, 2020 Now by this point I was losing it, stomping about the garage and generally being a bit of d**k, even Mrs K pointed out that if it wasn’t fun I probably shouldn’t be doing it ……. She is the voice of reason, so I walked away for a bit, but I’m a stubborn sod and really wanted quarter panels and a firewall, so with a coffee in hand I sat on my comfy chair and re-thought the problems, The top, bottom and middle rails create a flair as they go up so the top of the cockpit is wider than the bottom, a sensible design feature, but each rail is a different diameter and radius this cause issues in itself with the shape, secondly I was trying to copy the original panels which are set just inside the curve of the rails Although due to lack of quality control they couldn’t get that right or at least not hold it square while welding Made me feel better So I decided to approach it from a different angle thinking outside the box so to speak, This is now the off side as I didn’t photo all the nearside fabrication as I wasn’t sure this would go any better than the previous two disastrous attempts My biggest problem is the multiple radius so the bar in the middle was removed along with the metal plate (both circled in red above – other colours available) the that metal plate is the backing board for the electrical components but it’s in my way, I want to modify it and I wont be able to paint the back after I finish the firewall so I’ll come back to it later Offending rail All gone Then a quick repair to some damage I did when cutting the floor pan to shape No one will ever know A new template Transfer to metal Cut out Marked and onto the bead roller Gives us I needed a different dolly for this job – I just happened to have this very special one in the Shed It’s a custom dolly OK not just a bit of pipe in the vice Anyway it worked Now as I have overlapped the panel onto the frame you can cheat when you weld by starting the weld on the thicker frame then you “push” the weld pool quickly onto the thin metal and power off before it melts (well that’s the theory) Bottom rail weld Side bar Top bar Join the dots OK I’m engaging smug mode now – I actually think that’s pretty neat welding I can’t do to much linishing as it will weaken the ridiculously thin metal I’ll probably just use high build primer and a spot of filler to blend it before paint Any way it looks like this And the nearside got the same treatment Inside And the finished pair Thank you very much What a relief. Tomorrow I may post the firewall build, but I may put some time into the 2nd side project I have (I did mention it earlier) as I need that for the weekend – either way something will happen and the results posted for you to review Keyser - “He succeeded in being considered totally uninteresting. People left him alone. And that was all he wanted.” ― Patrick Suskind I hope he wasn’t talking about me 6 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 23, 2020 Author Share Posted April 23, 2020 8 minutes ago, SuperStu said: First firewall looked fine, just needed a bit of filler, some sanding and a splash of colour Trying to avoid filler if possible - I dont mind a thumb full to hide a weld line but don't want to shape the panles with it - It's probably me but the rugged off road thing keeps me away from filler I want steel - but Thanks for the input all comments welcome 1 Quote Link to comment Share on other sites More sharing options...
Stutopia Posted April 23, 2020 Share Posted April 23, 2020 1 hour ago, Keyser said: Trying to avoid filler if possible - I dont mind a thumb full to hide a weld line but don't want to shape the panles with it - It's probably me but the rugged off road thing keeps me away from filler I want steel - but Thanks for the input all comments welcome Version 3 looks mint. 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 24, 2020 Author Share Posted April 24, 2020 Good morning all, got a couple of hours in again yesterday and have a plan for the weekend but first I need to bring you up to speed on the firewall installation. So starting at the scrap pile I selected a sheet of 0.9mm mild steel – this is just standard sheet no coating so I thought best to use it before the rust gets to it. Well the rust is creeping in I used one of these paint removal disks for the grinder as this is only thin sheet and any hard sanding will weaken it. Got the surface cleaned up OK though I took a few measurements then put some weld through primer on the frame as again paint wont get a good hit on the back edges after the panel goes in. I started by cutting to size then marking where the frame rails will sit Then I marked up for some strengthening beads Ran those in As you can see this starts to put tension in the sheet causing a slight bow I then added 2 from the other side to help counter the bow Then one along what will the bottom as this does not have a rail to support it (yet) I also drilled it for the spot welds Some primer on the back face Clamped it in place and welded the top edge Then I clamped on a spare bar to keep the bottom edge flat before welding Then finished the spot welds and linished back Next I have to sort out the gap at the bottom and tie it all into the removable floor pan. Be Safe Guys n Gals – have a great weekend I will have hopefully have more on Monday for you. Keyser - “Do not whine... Do not complain. Work harder. Spend more time alone.” - Joan Didion 6 Quote Link to comment Share on other sites More sharing options...
Beb Posted April 24, 2020 Share Posted April 24, 2020 Work faster! We need more entertainment 1 3 Quote Link to comment Share on other sites More sharing options...
andybp Posted April 25, 2020 Share Posted April 25, 2020 Just caught up with this good work love the bead roller quite envious to be honest I thought you also had a Tig welder i find it good for different thicknesses of metal 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 27, 2020 Author Share Posted April 27, 2020 Morning folks, Weekly update from the Zed Shed – no work on The Bug this weekend as I decided I needed to sort a few little jobs and got into a couple more side projects – more on those in later posts But at the end of last week I finished the firewall So the job was to do this bit at the bottom, A good old paper template was needed Transfer to 1mm stee, bent and trimmed to shape Fits like this I used my magnetic “crickets” to hold it in place As I had my obligatory coffee before moving forwards, I was looking at the new panel and it just didn’t work for me – not sure why but I just wasn’t happy to carry on with it like that Its mostly as I have to tie it into the floor pan but can’t weld it as the floor pan is now removable So I binned it and went for a new design in the 3mm steel like this Now before I can fit that I need to take a look at the wiring loom and allow for the pipes, linkages and wires that need to pass through the firewall, it will be a lot easier to do that now rather than later, I did take some pictures to help me keep track, no doubt I will have forgotten something Wiring loom laid out Got my grommet selection out I settled on this lot Then a selection of annular cutters to make the holes (and more coffee) And finished with grommets tested for fit An annular cutter was harmed in the making of this post More coming ……………………….. 2 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 27, 2020 Author Share Posted April 27, 2020 Now it had all the holes in it I tacked it in place From the back it looks like this Then some filler bits for the corners Here is something fun, I have a rather nice saw bench for wood, after a bit of research apparently you can use it for steel as long as you change the blade of course, it took some searching to find a compatible blade but I sorced one and have been using it, it does small bits well and gives a lovely clean cut Used it to cut these, the curve was done with a flap wheel on the grinder Welded those in and finished the rest of the welds That just left these holes that need to be at least splash proof Marked up some 1mm To make these Which I didn’t photo fitted – use your imagination Bored of saying stay safe so Have fun instead Obut do stay safe Keyser - “I never really understood the word ‘loneliness’. As far as I was concerned, I was in an orgy with the sky and the ocean, and with nature.” ― Bjork (lets just not go there ) 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted April 28, 2020 Author Share Posted April 28, 2020 Hello again, I’m still at it but as promised I’m gonna mix it up with a side project, which you may or may not find interesting Long Pic Heavy Post follows - I decided to have a play with the milling machine I got a fly cutter with the first milling machine that I have never used but to use it I needed an oil feed and cooler, as I don’t have a catch tray on my mill I cant use the recirculating pump. To solve this I ordered an atomiser from China (because silly cheap) last year it took 3 months to get here and has been sat in the draw ever since. So I got me brand new BLACK! eBay trainers, purchased just for the Shed – with Velcro so I can take them off easily to go in the house (I keep bringing metal bits in ) Lovely shade of BLACK are they not? I started by getting out my box of airline connectors and found a load of bits Drilled a hole in a bottle top and fitted the oil pick up line Found this old clamp Cleaned it up and welded this plate to it So I had something to hold the atomiser steady That goes like this Side Note – Angle grinders are strange – blow up 1 get 2 back Made up an air feed with regulator I use plastic airline, but don’t have any, it just so happens the connectors work on 15mm copper and I did have some of that – That gives me all the connections I need Next to the Mill itself Needs a clean …. Ta Da Now to test the fly cutter on a bit of old steel That I cut off the mobile welding table I made…. This one Using this If that’s not a recommendation for these saw’s I don’t know what is To the Mill – first side Some time later Wow – I like it A hole is needed Then some more old box section Back to the mill and some more time later Now weld a support bracket onto the first bar And the box to the bracket I love welding heavy metal Warning – the following contains the destruction of 350z parts – viewer discretion is advised Old exhaust end If you cut the back off You can take out the inner bit To leave More old box Yes even more time later Weld that all together Then change the design And hide the evidence Add some straps Add the stainless exhaust – first time welding stainless to mild steel and something that thin to something that thick but it Tig’d up OK Off cut of worksurface from Mrs K’s kitchen refurb And we have ……………………… Now I can keep my tools to hand at the Mill And the oil won’t get knocked over Over engineered? Probably but it was good practice and I now know that my Fly Cutter works Be safe all. Keyser - “Better to remain silent and be thought a fool than to speak out and remove all doubt.” – Abraham Lincoln (maybe I should have listened to Abe? ) 4 Quote Link to comment Share on other sites More sharing options...
veeg33 Posted April 28, 2020 Share Posted April 28, 2020 A tiny bit over engineered but I love it! I always wanted shop air in my garage but can't justify it when my garage can only fit my zed and some bits n bobs. 1 Quote Link to comment Share on other sites More sharing options...
andy james Posted April 28, 2020 Share Posted April 28, 2020 The old keyser would have had 2 exhaust tips welded on the table for the bottle of oil and a full fat coke! Nice work buddy. Maximum effort and slimming!! 1 Quote Link to comment Share on other sites More sharing options...
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