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Re-body My Zed


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On 06/05/2022 at 04:30, Stutopia said:

This is so close now I can smell fresh lacquer. Absolutely stunning build mate, thanks for detailing it on here, been a fascinating follow.

 

I may have missed it (or forgotten), what colour will it be?

Hi it will be mostly white with red , Black and silver graphics , I have the livery in my mind but I am not talented enough to do a rendition sorry , I would love it though .

Thanks for fallowing along .

Cheers Phil

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Hi everyone as you know I am losing the fiberglass shop soon , not sure exactly when , I am going to ask for an extension to get the molds done on the big parts , like the whole back and front of the cat before having to move it .

Ok enough of that depressing thought .

 

Alright a while back I had to change part of the trunk area , i thought it was too tight a curve and might be a problem or a weak spot in the trunk lid , it's a bit confusing even for me lol so I will try to explain as it goes along .

IMG_20220504_131221390.jpg.6daa78e0405d9118bfae8b899aa73694.jpg

 

So now I have to remake the part that goes to the back of the car ,from where I cut it off .

This is this going to be the new plug for the new bottom of the trunk ( boot ) lid

( I have to temporarily fill in the slots for the wing )

 

IMG_20220504_140922522.jpg.3466245c46d74757545de20d4767cbca.jpg

 

Ok you see the part on top of the yellow tape around the trunk opening , well that from the original one I made .

But where it turns at the bottom it was too tight and I didn't like it , it got too thin in ths area and i was afraid it would break .

So I made the turns softer right where you see it cut off .

 

IMG_20220504_145535382.jpg.72927cd39190cb319aa241adb2cc797d.jpg

IMG_20220504_145557055.jpg.56ee3a42f33ca0e082b08de538571fba.jpg

 

IMG_20220504_152050404.jpg.2db0a3154d51852856608abcb518d4e2.jpg

 

I glued in a piece of wood and just taped over it 

 

IMG_20220505_114019167.jpg.a63a01aba03fc678bebb1a4924328e83.jpg

 

next is to simulate the back outside edge of the trunk lid with the piece I made earlier for this reason .

 

IMG_20220505_114027996.jpg.56a74506264ce8002c5ff803b009ab7f.jpg

 

IMG_20220505_114411257.jpg.e64b5ddd1c2a29a40b2496ed3bfada55.jpg

 

IMG_20220505_114805776.jpg.008e3c8d3010ad951d3eb445532c7452.jpg

 

Here I glued 2 pieces of 3/16 ths together to mark the edge ( couldn't use a square because it's on an angle )

 

IMG_20220505_114813432.jpg.b4312311778d532e0bcb018b7e6c0817.jpg

 

IMG_20220505_115601786.jpg.bb7d5fa8a5847cbb36de7aeb9153fd4e.jpg

 

This get cut off , as it represents the gap for the bottom of the lid to make clearance 

 

IMG_20220505_122943931.jpg.0fbdb9d384bd5894c09c912cf238ee36.jpg

 

next is the foam core to make the bottom , now this was cut for the previous version  , so it will need to be modified

IMG_20220505_155835278.jpg.810b4002f38ba29eed99cb0fd563d62b.jpg

 

these are spacers to support the foam core underneath , and will give clearance for the rain water escape , they get glued down temporarily 

 

IMG_20220505_155852891.jpg.ba0bd8ec13eeb32ad8969f42a611861a.jpg 

Hear you see the back piece is set back so the inside face will become the finished face , I know confusing ....

 

IMG_20220505_161756876.jpg.3d3b183d16f50329c1ada207d03ba62a.jpg

 

next is gluing a piece of foam core to the top of the back edge to make the bottom flange to bond to the bottom of the top part of the lid .

 

IMG_20220505_161935953.jpg.05d9aceb70ae971dc07a3b848fe6d066.jpg

 

IMG_20220506_120144958.jpg.b987f311656eaa885c2504e0ab0249fa.jpg

 

IMG_20220505_174141973.jpg.1add6fd3d532086285f78bc95cceea41.jpg

 

it gets taped to seal the edge of foam core , and you can see I am making some patterns to add foam core to the large base cover where I changed the corners .

 

IMG_20220506_120801179.jpg.d7652012833d146897739e7f889685ec.jpg

 

the black line represents the edge of the base cover , so I need to fiberglass this area to match the top part around the opening .

 

IMG_20220506_120805586.jpg.d59cea6e03d4e7d28cd4c2bada167493.jpg

 

IMG_20220506_124845230.jpg.d28f2ebeb3da57d695ebf0add95cd518.jpg

 

Here I am adding some thin aluminum flashing to the upper part to run the fiberglass on , this will allow extra space for an even thickness later when making the part .

( I know I don't have a pic crazy ) you will see when its back on the car .

 

IMG_20220506_124855038.jpg.80cbfa99a0ec6558e8bdb70c73876f51.jpg

 the bottom side

 

IMG_20220507_110844587.jpg.9a4559de00911f6c5fc89787cfa0cc67.jpg

 

this line shows me how thick the fiberglass needs to be to form the proper gap

 

IMG_20220507_115738176.jpg.2773748da52e90215b164d332a0fe66c.jpg

 

checking to make sure it level and figuring out a pocket for the Hinge to go in .

 

IMG_20220507_132248712.jpg.9472cdfd44d2a8276100dee830c4f71c.jpg

 

flashing to make the form extensions for the back sides

 

IMG_20220507_143938432.jpg.afb222938273915a47be9d0a9466813c.jpg

 

they have little dams where the new piece needs to terminate 

 

IMG_20220507_144006488.jpg.bae2694990f509ea16ec3d06cdceb008.jpg

 

IMG_20220507_144020503.jpg.27098d0f163b1713fadcefdf595b25fc.jpg

 

IMG_20220507_144035894.jpg.615b7389f2dd07a707a103b3beaa0a76.jpg

 

these will get waxed so it will release after .

 

IMG_20220508_161939821.jpg.1ce82046312cb81b762d84d15d07a9ef.jpg

 

a few layers of glass

 

IMG_20220508_161954652.jpg.714aad44819d7757c492127e116b6a8b.jpg

 

IMG_20220508_162000875.jpg.c2d903a2c017d34e2d8a349cfcf1033e.jpg

 

IMG_20220509_103447553.jpg.32646f69015723c240b7fd1efba40c26.jpg

 

here i remove the end dam and the turned up part will get trimmed off to match the top 

 

IMG_20220509_103644812.jpg.3e61a055e222e84b4336613a8ad82557.jpg

 

IMG_20220509_104724393.jpg.800eab2531f4eca8101aa7cac9138ccd.jpg

 

trimmed 

 

IMG_20220509_104730531.jpg.2d675e3e3cea777540cefa6f2ede901f.jpg

 

and the RHS  

 

IMG_20220509_104801345.jpg.7f02725cc79b804caf930008b2805150.jpg

 

IMG_20220509_105034721.jpg.933f48c625473140a63aeae45406761f.jpg

 

IMG_20220509_105426730.jpg.019f9294115017a2e171be591b714c1a.jpg

 

test fitting the foam core base before adding to corners that nee to be altered

IMG_20220509_113024791.jpg.c4881d52898f7d153b4c76b1f588d258.jpg

 

IMG_20220509_113126343.jpg.6ca735ff18e58a7ecc74e59108ba688b.jpg

 

IMG_20220509_135807594.jpg.6f00b1333f51fc5691d26dc13231be6a.jpg

 

here you see the flashing on the upper part , which now get temp glued to hold for glassing .

IMG_20220509_135823767.jpg.4b32c6a9a92f95c398e9e1ecee2cfcc7.jpg

 

IMG_20220509_135845308.jpg.31ba26810f795fd2a0d13c18f7632bd2.jpg

 

IMG_20220509_153409926.jpg.14bd2bf4a557be5e13367eabfb374224.jpg

 

making the addons for the foam core .

 

IMG_20220509_163544602.jpg.72355f72cba22042fc837b4a6cbeb799.jpg

 

testing the addons 

 

IMG_20220511_144933795.jpg.43cd30d386198b349a9e6c395c3781cd.jpg

 

it's good so the base gets held down temporarily with 2 sided tape ,can't fasten from the top , no access after it glassed to remove it from the car

 

IMG_20220511_144944232.jpg.4b4f29f1b5e80a14359d76aeaf7dc59c.jpg

 

IMG_20220511_145117078.jpg.6d5e11275bc1d1f994b523e8252ce396.jpg

 

when it\s lined up and ready just press down evenly  only one shot at it !!!

 

IMG_20220511_145807814.jpg.80789bed3161a8638142392bf05fd330.jpg

 

next is to add the foam block which will be the pocket for the hinge 

 

IMG_20220511_152948556.jpg.01469ccf4a02965192dee2192c50e2ac.jpg

 

I am kind of cheating here , normally you would glass over this and bodywork it etc before glassing , but I am under the gun to get everything glassed now that can't be done off the car , because of the move and it will be easier to bodywork from the other side and off the car . so I am just taping the foam and the edge seams , kind of an experiment  , hope it works !!!! what could go wrong lol 

 

IMG_20220511_160421464.jpg.8485249831aa63893694794a2d9b8b5f.jpg

 

IMG_20220511_160449927.jpg.4827757b77809577000f939c2378f617.jpg 

next is a few coats of wax and spray with PVA mold releaseIMG_20220511_161802420.jpg.67ca4082924ae41b32a4154e26800373.jpg

 

cut all the material before getting sticky 

 

IMG_20220511_162317070.jpg.f4648fabcf3064908ee3d315be7a23df.jpg

 

IMG_20220511_162753456.jpg.a3ad0aac903e1c0820d9d64fd6381fbd.jpg

 

IMG_20220511_173415390.jpg.9e42d6c1c75e022eec62dde9c4b0d8f1.jpg

 

IMG_20220511_172514567.jpg.915b44236daa9a44916dabd4109aaf6e.jpg

 

a few coats of PVA

 

IMG_20220511_172602595.jpg.89ae1125829eda8bebcd0af4941ee40d.jpg

 

IMG_20220511_173129079.jpg.ac1609337313586029da1f789677d018.jpg

 

and we are ready to glass stage one 

 

IMG_20220512_142809291.jpg.d661889522bdd80cdff568ac7cd05725.jpg

 

IMG_20220512_142818752.jpg.0910da315999745336880119ed58db13.jpg

 

IMG_20220512_142836544.jpg.ee4603fc2faf68fe9b6032071d087951.jpg

 

IMG_20220512_142857031.jpg.0680bffde935abe7d09bb29cea364e4d.jpg

 

Ok looking good , on to stage two some stiffeners to keep the base in place and firm for body working the other side , going to make them out of foam with a 45 degree edge that's easy for the glass to go over 

 

IMG_20220513_113739689.jpg.67c6c22a802f3c23a254f70c5988de2b.jpg

 

if I tape them back to back I can bevel them in the router table 

 

IMG_20220513_114054417.jpg.83e072423bdc9b42ce366a2fde766655.jpg

 

IMG_20220513_115808532.jpg.5c15b4d766599b161c79c0a1b7254d1f.jpg

 

IMG_20220513_115834786.jpg.a3e271827fb63a654aa2c27915b32ada.jpg

 

a quick sand and they are ready

 

 

IMG_20220513_124427990.jpg.59bab68ba998808ee30871f76ff21785.jpg

 

next is to lay them out and glue them down 

IMG_20220513_131746004.jpg.08ea89622df6f8b40f024db70e5ca5ff.jpg

 

IMG_20220513_131800933.jpg.6eb131b7b1db2317831408fb525c0d45.jpg

 

IMG_20220513_131822429.jpg.59a05b2091604e785fc2f5837fe4b63a.jpg

 

IMG_20220513_133922665.jpg.18533ffe66de4553360dade80e7f0196.jpg

 

next is to prep some material and glass them

 

IMG_20220513_141108794.jpg.dad32c0d4ec0f9caf63ff046317d90eb.jpg

 

IMG_20220513_141129117.jpg.bda315f4333fe265c0d0a5bf900d203c.jpg

 

IMG_20220513_161051351.jpg.bfe9f529228c57d58b0190cc380eca0e.jpg

 

IMG_20220513_161057563.jpg.eafbbb55e8d7fbec8b1f4b7d98abe282.jpg

 

IMG_20220513_161118254.jpg.a8a4874843277e8791859412f64f21bb.jpg

 

IMG_20220513_161128424.jpg.5c5c84471ddbafed7ccaa48b82e29005.jpg

 

Well I am happy with how it turned out , I know its probably a little boring but its all part of it .

This morning I will pop it off the car and trim the edges 

 

thanks again for all the comments and support , would have loved to do a YouTube series on the build but I would have needed someone to shoot the vids and help produce it it takes about 3 hours a day , unfortunately I just don't have the time , maybe I will do one on installing the body on the car , let me know what you think .

Cheers Phil

 

 

 

 

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Hi everyone last update on the trunk lid bottom plug .

This is always fun an a bit nerve racking getting the part out !!!

 

IMG_20220514_110053560.jpg.7965c3572bb67a2f54fb25e10436cc5f.jpg

 

Starting out with a thin flat pry bar it get under the edge , then put wedges in all around where you can 

 

IMG_20220514_110108968.jpg.4fd28d66350206456567d4d9a15281c2.jpg

 

IMG_20220514_110058868.jpg.f0eb2e057dba92222b20be0450d64235.jpg

 

IMG_20220514_111347340.jpg.b64cd0cb156a7ce46172c9d958187134.jpg

 

the danger here is breaking something on the car by prying or breaking the part , if it's a finished part coming out that is gel-coated you don't want to scratch it with tools such as screwdrivers .

IMG_20220514_111548230.jpg.b821b33e066f40a33ec62757da43d7bf.jpg

 

I found this little gem at the tool shop on day in the line waiting to check out , it goes flatter than a piece of regular cardboard and you inflate it , it's very strong , I bought the smallest one to try it out , next time I am there I will get another one for sure .

 

IMG_20220514_111804930.jpg.276c908434ccc8e9d1e99db868d4d89e.jpg

 

here you see it under the part , it's great because it's not sharp and can press on a larger area .

I took a couple of videos and will try to put them on .

 

IMG_20220514_112852355.jpg.48640088930966e77d32182d41688537.jpg

 

IMG_20220514_112905782.jpg.4f5894ef7fb042a236bd15d43363c234.jpg

 

IMG_20220514_114144608.jpg.d5e524e1b4614fa52f41749f58e8524f.jpg

 

got it off the car ok , now to clean it up , trim the edges and wash the remaining PVA off  , it's great stuff also it washes off with water .

IMG_20220514_114200988.jpg.12c217f3cd880cb8e9a39611a1aa4b90.jpg

 

IMG_20220514_114222762.jpg.36c4feed290646dd837f6f88a5ff5f45.jpg

 

IMG_20220514_124808576.jpg.96d4eaafe98428e9c97c6dd1b5547bde.jpg

 

IMG_20220514_124816241.jpg.8b06f38c65e2b63d8e54c76be2b7d8a4.jpg

 

still need to sand the edges 

 

IMG_20220514_125246069.jpg.4dea4685a5c985deadb37f311bd01495.jpg

 

As you can see the carnage from the temp setup to make the part 

 

IMG_20220514_125256600.jpg.128ea25f50495e7021226d997a3b0e3f.jpg

 

IMG_20220514_134357549.jpg.8637111ae7b379e36ffe4cbf7e0f1c7d.jpg

 

the back

 

IMG_20220514_134412752.jpg.13b3cfd5e89177f1773e74f7f76b8c33.jpg

 

the front with the pocket for space for the hinges

 

IMG_20220514_134614869.jpg.959decfc02f98f9d6b463111d01abb40.jpg

 

test fitting looks great !!

 

IMG_20220514_134703586.jpg.035c754692ed99aaf60b39d8d9c4c10e.jpg

 

It still needs to be bodyworked and then make the proper mold for the part  , so the finished part has the finished side on the out side , fiberglass is such a lot of work , you need to make three things to get one .

1 the plug

2 the mold

3 the part

but once you have the mold you can make lots of them .

IMG_20220514_135638647.jpg.f155fc8e1c9b418a3e06a5ccd418e9b4.jpg

 

you see here there is clearance for the part to fit in .

 

Next will be jumping onto the roof , although I feel like jumping off the roof sometimes lol lol

IMG_20220515_151145212.jpg.8c0fe8dbca1c0abf9c66a447bf1b640d.jpg

 

this is the part I started to make a while back too attach the roof scoop , not too sure if I like it , it's going to be a bugger to glass and mold , been thinking of a better way .

 

IMG_20220515_151222222.jpg.5eafd85d0ba770becd4274a89a321962.jpg

 

IMG_20220515_151255304.jpg.4eafa22a7417484be850ad11ccbb1e5f.jpg

 

While I was sitting thinking about the roof I got out the masking tape and laid some on the side of the car to get an idea of it filled in .

 

Wow Can't wait !!! to do the doors now ......

IMG_20220515_161206664.jpg.705646247d40e756caa3d364fdc64971.jpg

 

35265949_IMG_20220515_1614581822.jpg.44d2fcebbf1d9120fc29c07ca1087a09.jpg

 

741527691_IMG_20220515_1615301762.jpg.bef07debdca1d1d5b8a66dc214bd1005.jpg

 

IMG_20220515_162734200.jpg.6b004a9ad495dfe0e500c8b3395e2a93.jpg

 

1649335801_IMG_20220515_1615403072.jpg.fcaac230864d2f1fb08539b856c13b58.jpg

 

IMG_20220515_163723857.jpg.6373e6d7744bd495b8898cad41ec6551.jpg

 

Enjoy !!

 

Stay Safe and Stay Tuned In !!

Cheers Phil

 

 

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