Re-body My Zed

[LRF4N]

The front has an alfa giulia vibe about it. What are the tail lights from? I thought corvette when I first saw them

[ShortPaul]

Just wondering what rims do you have in mind to fill those arches with

[Falcata]

6 hours ago, LRF4N said:

The front has an alfa giulia vibe about it. What are the tail lights from? I thought corvette when I first saw them

the tail lights are from a 2017 Camaro , the ones on the car right now are the stock ones ,they were brand new take off's which I picked up to build the car with .these are the lights that will go on the car when it gets assembled .

They are sequential ,they also come blacked out .

I am a dealer for them now and they are a little expensive so I didn't want to use them for building the car. 

 

 

Edited January 22, 2021 by Falcata

[Falcata]

2 hours ago, ShortPaul said:

Just wondering what rims do you have in mind to fill those arches with

I have picked Savini wheels , I went to SEMA in 2018 and saw these there .

(I have never seen so many wheels in my life in one place)

The rears are 22 X 13 and the fronts are 21 X 9 1/2 with tires they cost  $6800.00 Canadian .

So that's why I built wooden ones to work on the car , the wooden ones are 24 inch ( but no tire the blue foam represents the full size )

 

 

 

[Falcata]

 Back to the rear deck lid or trunk , I needed to make a copy of the deck lid trunk area so I can build the trunk lid top and bottom off the car , it's so wide that it's just too awkward to build on the car .
So I prepped the area with wax and PVA as usual , but something went wrong , still not sure what happened , as I was laying up the fiberglass on the third layer, I was half way down the lid and it started kicking off and I wasn't going to be able to steel roll out the air !!!
So I was freaking out thinking it's going to be a big mess with air pockets and voids !!!

I would have to grind it all off so I pulled all the layers off and tossed them away , leaving a bunch of little glass hairs everywhere to deal with .

I got it cleaned up as best I could and re glassed it.

 

  

 

Here you see popping it off the car

  

 

Here you can see the blue foam melted from the heat and some resin got past the plastic and tape , and the part was not great and needed a ton of body work to rescue it

 

  

 

I built a base for it , makes life so much easier to work on it .

 

 

  

 

  

 

so now this will get glassed and become the the simulator for the rear trunk area , so I can work on building the lower and upper halves of the trunk lid with out hanging over the car for hours .   

[Falcata]

the trunk area copy , now this will be easier to walk around and work on .

Here is glassing the part

 

 

 

Yes another base this one is important because it will also hold the part at the proper angle so it will look right on the car .

 

 

Here are the two pieces being separated from one another .

 

 

 

 

 

 

[P15UL T]

Your wooden Jigs are as impressive as the fibreglass 

So are you making molds of all parts so you can make extra parts should you damage anything while driving it? 

 

 

[DoogyRev]

15 hours ago, Falcata said:

$6800.00 Canadian .

Assuming you're in Canada then? Where abouts?

 

[Falcata]

8 hours ago, P15UL T said:

Your wooden Jigs are as impressive as the fibreglass 

So are you making molds of all parts so you can make extra parts should you damage anything while driving it? 

 

 

Hi I am planning on making really good tough durable molds , I have a buddy who wants one , plus you are right about being able to make more parts in case of a crash or something .

Thanks for your interest .

[Falcata]

47 minutes ago, DoogyRev said:

Assuming you're in Canada then? Where abouts?

 

Hi DoogyRev

Yes I am in Canada , I live in Victoria on Vancouver Island .

[DoogyRev]

35 minutes ago, Falcata said:

Hi DoogyRev

Yes I am in Canada , I live in Victoria on Vancouver Island .

Awesome, I am the other side of Chilliwack at the arse end of the Fraser Valley 

[Falcata]

Started using the new foam , its going to help a lot , I can cut the foam with the new saw I built and then run it through the thickness planer to what ever thickness I need .
Here you can see how malleable it is when thinner .

  

 

  

 

  

[Falcata]

So this is how I make patters sometimes with thin door skin wood , rip it into strips about an inch to one and a half and glue gun the pieces where you need the shape .

Then trace it out on paper then transfer that onto the material your using . 

This is to make the pattern for over the tail lights , and you use the same one for both side ( of coarse )

 

  

 

  

 

 

[Falcata]

So All the parts I made with the blue foam has to be replaced with the new foam , lucky for me I saved all the patterns and jigs for the router table .

Here I am remaking new foam parts that go on the roof , I call them the batman humps , there purpose is to make the roof stronger and provide some more height around the trunk area .

 

First pic is the 1/4 inch plywood pattern

 

 

 

Running the foam through the thickness planner

 

 

 

 

 

 

 

 

 

 

 

 

[Nismoandy]

Really great, lovely to see the skills that go into this build 

[Falcata]

Should have a look at the hood .

I mocked this up with the blue foam , was a long time ago now , this was the original plan for the hood , Vintage Maserati kind of style .

The two outside petals were going to cold air intake slots underneath were the air box's are .

but as time goes zooming by and the amount of work to build molds for all these parts is just unrealistic  , it's been over 2 years now working every day .

The other thing is it doesn't make any extra room underneath for extra goodies .

But I really liked it !!!

 

 

 

 

 

 

 

Edited January 23, 2021 by Falcata

[Falcata]

This is the bottom half of the hood , makes lots of room for goodies , I plan to buy another Zed later and build a beast with a supercharged LS3 6 or 7 hundred horsepower , full cage  , bare minimum , so I want some room for stuff , this new hood design will allow room for twin turbos or LS style air intake .

So I had to build this with the blue foam , so happy to done with the blue foam , it's truly a pain in the butt ,having to seal it up with foil and tape  .

 

 

 

 

 

 

 

 

now remember is is the bottom half .....so the top will be a lot different 

[pintopete58]

Being a fellow bench joiner/ carpenter&joiner I can really appreciate how long these jigs  can take to make.  Being old and decrepit the best I can do is a Mason's mytre on a kitchen worktop .will watch this with upmost respect. Keep it coming 

[ShortPaul]

1 hour ago, pintopete58 said:

Being a fellow bench joiner/ carpenter&joiner I can really appreciate how long these jigs  can take to make.  Being old and decrepit the best I can do is a Mason's mytre on a kitchen worktop .will watch this with upmost respect. Keep it coming 

Can you do a mason mitre out of square? 

[pintopete58]

I did say with upmost respect  Paul 

[pintopete58]

Out of square is easy 

[pintopete58]

It's like a clock you start at 3 o'clock & rewind to 5 two 3 or 5 past 3 

[davey_83]

Truly AMAZING!!! Love the skill and passion

[LRF4N]

Really enjoying watching this come together. What stage are you at at present and when will it be complete?

 

 

[Falcata]

20 hours ago, LRF4N said:

Really enjoying watching this come together. What stage are you at at present and when will it be complete?

 

 

Hi I am almost caught up on posting where I am at , hoping to have it done by late spring or mid summer .

Thanks for your interest .