The Fake Jaguar Thread

[Ulu]

This week was kind of a bust. We had a storm that messed up the boatyard. I spent some time cleaning up, then I caught some stomach bug that spoiled my week.

I did make an extension for my brake pushrod. I also made a floor for the battery tray, some small frame reinforcements, and a pedal stop, but none of that is welded yet.

I got some better brake lines flared up. I still have to bend and install them. This old one was too short.

But there is where the little brackets go.

I won’t install the brake lines yet. I want to install the front axle at the same time, but there is bottom welding yet to do on the frame. I should paint the bottom first too.

I took off the forward pivot clamp business for access to the brake lines, but it will be reinstalled soon.

 

[Ulu]

I decided to finish the car just enough to get it back in the garage. It will start raining soon here, and I hate rust.

I’m making heavier floor panels.

I reimagined the whole front floor as a structural diaphragm and was then able to reduce gusseting requirements.

This is the new battery floor. I put a lip on the flange with this little slotted rod.

(All the heavy junk is just to hold it on the bench.)

This next panel goes in the rear bay.

I’m forming lips and flanges by hand.

Making the notches and bends.

Now I just need to dress the corners and fit it in.

Then I can remove the unwanted paint and weld these in.

 

[Ulu]

I had a bad reaction when I tested that existing paint. I sprayed some rust-converting black primer on it and the edges curled instantly.

I spent half a day removing every molecule of paint on these panels.

Sandpaper and wire brushes finally made it all ready to weld.

 

[Ulu]

I thought I was going to get to weld, clean and paint a little bit today; but instead I ended up working on my garage door, again.

For some reason it just would not close and yet when I disconnected it from the closer required almost no force at all to close the door.

I had several problems with the travel limit adjustments, which are all made out of plastic gears, and 40+ years old now.

Part of the solution there was an easy one. I just set the door so it didn’t open as far, and it didn’t close under force.

But after variable results, I finally determined that the closing force adjustment potentiometer (which was turned all the way up) wasn’t actually working at all.

I bridged across it with solder and a tiny piece of wire. This is essentially the same as turning the “force” knob all the way up, forever.

It’s not as safe now but at least it still has the electric eye, to prevent it from crushing small animals and children.

 

[Da Gas Man]

 

[Ulu]

No animals were children were harmed in the production of this vehicle. So far. So far as we know….

Today I managed to get the floor panels tacked in. The truth is that each one got about 50 small TIG weld‘s.

Now I need to flip it over and weld them on the other side.

I also welded in the pedal stop which I didn’t photograph, & I fixed the brake cylinder pushrod.

This is a stock pushrod that I extended by cutting it and welding it into a long 3/8”chrome vanadium socket from SK Wayne.

This Just Happened to be exactly the size I needed, and some contractor had left it laying in my yard, so it didn’t match any of my tools.

I also welded in these little corner brackets which help tie together the rear of the frame.

The pink arrow is just pointing to a weld, that welds to another weld, that is on top of yet another weld. It’s complicated.

Anyhow it turns out I made 136 welds today, but over half of my time was actually spent cleaning the things that I needed to weld.