Falcata Posted January 17, 2021 Share Posted January 17, 2021 Hi everyoneI am building a complete new body for my Nissan 350 ZI have and been at it for almost two years and can finally see some light at the end of the tunnel . Getting started I built a dust collection system that spins 360 degrees because as we all know fiberglass dust is no fun , next was to build some wooden wheels to simulate the new wide ones to help with clearances and fender lips . the rear hatch and window is deleted and replaced with a smaller trunk lid . 11 Quote Link to comment Share on other sites More sharing options...
ATTAK Z Posted January 17, 2021 Share Posted January 17, 2021 (edited) Wow this could be good - welcome to the forum Edited January 17, 2021 by ATTAK Z Quote Link to comment Share on other sites More sharing options...
Nismoandy Posted January 17, 2021 Share Posted January 17, 2021 This work looks amazing top quality well done Quote Link to comment Share on other sites More sharing options...
andybp Posted January 17, 2021 Share Posted January 17, 2021 now we're talking this is the first time in a while that i've been interested an any projects on here so get to it fella Quote Link to comment Share on other sites More sharing options...
P15UL T Posted January 17, 2021 Share Posted January 17, 2021 Yes yes yes. Love this. Been doing some simalir work with a custom wide body. Quote Link to comment Share on other sites More sharing options...
andy james Posted January 17, 2021 Share Posted January 17, 2021 Oh Lordy. Looking forward to updates. Welcome along chap. Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 Thanks for the kind words chaps , I have over 1000 picks of the build so hang on for some cool stuff !!! Lets continue with the rear hatch / trunk of the car shall we . Ok this piece is a buck to make the cover for the rear suspension tower brace . I was originally planing to have a small rear window , but I just couldn't get the the water to flow over the suspension brace , so with all the rear view camera tech out there I decided to delete the window all together 1 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 Continuing on with the rear deck area . Building the trunk ( rear bonnet ) opening This raised perimeter once glassed will be cut so that there will be a standing edge for the trunk seal to slid over my plan was to cut this guitar shape out after the rear deck was finished and it would become the bottom of the opening lid . Next is adding some stiffening to to this piece with some bars going across . I use lasers levels to help keep everything as level and symmetrical as possible . 4 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 Some more on the rear deck area . Taping up the underneath in case any resin gets through here I am making patterns to trace onto some super thin fiberglass sheet that I made to go in here Here is the thin glass 4 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 Roof Scoop , this sounds easy to make ......first the cardboard mock up then foam board , we can't get the green foam board the guys in the US get which you can glass right over , the blue stuff melts with just about anything you touch it with , so i cover it with tinfoil first , what a pain , because it's great to work with you can cut shape sand all very easily .The roof scoop is just for the cool factor plus it helps keep the roof rigged , and will be removable to change the windshield if required , and house the third brake light . I have to say now in retrospect , if I was to build this again I would not have done it this way , it took way too long . But it turned out ok in the end . 4 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 (edited) some more on the roof scoop , like I said it took way too long ........ The nose cap will be how the front gets attached to the roof to hold it on Edited January 18, 2021 by Falcata 3 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 time to glass this thing !!! When I make molds I like to build a base for the part to stand up , it makes it so much easier to work on . 2 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 I decided to make the mold two parts so I wouldn't bust the part trying to get it out . I made the end cap removable here I am taking the plug out Here is the mold with the black tooling gel coat the mold prepped to make the first one white Gel coat laying up the fiberglass removing the part roughly trimmed up and on the roof I made this part in the winter and had some issues but it still very serviceable 5 Quote Link to comment Share on other sites More sharing options...
zelda Posted January 18, 2021 Share Posted January 18, 2021 Wow. You have some serious skills. Anything with lasers gets my vote 3 Quote Link to comment Share on other sites More sharing options...
valy Posted January 18, 2021 Share Posted January 18, 2021 now this type of project I do like looking forward to seeing how this takes shapes 1 Quote Link to comment Share on other sites More sharing options...
Payco Posted January 18, 2021 Share Posted January 18, 2021 if Carlsberg made a 350z DIY body kit mod man !!!..Incredible skills and effort. Watching with interest. 1 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 Thanks for the kind words , this project is a huge undertaking , I am not a composite expert by any means , i worked in a custom yacht place over twenty years ago , now of coarse there are many new products and Technics . So lets move to the front of the car . Headlights are Mazda 3 the aftermarket Angel Eyes ProjectorsHad to make pots for them to bolt into , I tried to make the Plug for pots with two part foam , that didn't work very well , so I made them out of wood , as usual that was a pain in the butt , and a ton of work to make one part , as these pots will become integral with the substructure . 3 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 More front end , i decided to build a one piece structure to support the headlights and the front fenders and the bumper cover and the splitter , with fixtures for the air ducts . Again wood.....not the best because it's so porous it soaks up everything so it needs to be sealed before filling , painting etc . I have spaced out the factory bumper 2 1/2 inches to make extra room for inter coolers and or oil coolers . The factory impact foam will be retained also it's a shame all these pieces being made to form the fiberglass all go in the bin when the car is complete I made a copy of the bottom of the factory hood so I could see for clearance to add or remove space , I had some old resin that had some chunks in it from being in the cold , so the quality is bad but is going in the bin later anyway . Also retaining the factory tow hook !!! This is the upper section of the substructure . 4 Quote Link to comment Share on other sites More sharing options...
ShortPaul Posted January 18, 2021 Share Posted January 18, 2021 Nice work unbelievable amount of labour, very interesting project you have on the go there 1 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 18, 2021 Author Share Posted January 18, 2021 (edited) I have time for one more post before heading to the shop to work on the car ( everyday ) I should have glassed this front sub structure at this point , but I was too excited to see some shape in the car More front end ....Fun with foam !!!!!! the foam cuts and sands like butter , it's very easy to go too far . Here you can see making a moat for the two part Polyurethane foam I carved this all by hand , a large bread knife works quite nice for the initial shape I built a device to measure , its like trying to measure an egg . Edited January 18, 2021 by Falcata 5 Quote Link to comment Share on other sites More sharing options...
P15UL T Posted January 18, 2021 Share Posted January 18, 2021 Foam Friend lol. That's some work you are doing. Ive completed my molds for the wide body arches but still to do the front and rear bumper. Takes so much time when you are just doing it for an hour or so each night. Paul 2 Quote Link to comment Share on other sites More sharing options...
Flashback Posted January 18, 2021 Share Posted January 18, 2021 Incredibly interesting project and some great skills to try doing this all. Top marks to you! 1 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 19, 2021 Author Share Posted January 19, 2021 7 hours ago, P15UL T said: Foam Friend lol. That's some work you are doing. Ive completed my molds for the wide body arches but still to do the front and rear bumper. Takes so much time when you are just doing it for an hour or so each night. Paul Hi Fellow Foamer Wow , you are pretty trusting not to get that foam on the wheels or anywhere else , nothing takes it off !!!! I got some on my tool box and its there for good , I will check out your car after i post some more stuff . I don't know if you have tried this but I learned a trick when doing my front fenders , take the time to put that clear packing tape on the inside of your cardboard dam and put mold release wax on it , helps the foam spread and stops the cardboard from sticking !!! comes out smooth . Cheers 2 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 19, 2021 Author Share Posted January 19, 2021 I must thank everyone for all the positive feedback , it helps two years in 7 days a week . Some more of the front shall we . I built this device to measure to insure both sides come out the same . I might look int lasers and scanning before the final filling and sanding . 3 Quote Link to comment Share on other sites More sharing options...
Falcata Posted January 19, 2021 Author Share Posted January 19, 2021 On to the fenders I made copies of the factory ones for a couple of reasons . First I want to use the factory fastening for most of the top and bottom , and second the wheel arch size , shape and it helps with location for the new one . Next I used some 1 x 1/8 flat bar and 3/16th round bar to set the shape of the new fender , once I was happy I tack welded them in place . 3 Quote Link to comment Share on other sites More sharing options...
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