Falcata Posted October 27, 2021 Author Posted October 27, 2021 Hi everyone Just some more pic's of some small changes to the rear lower panel. Added a little foam and some filler to the edge where the scoop exits , not sure if i like it , yet , might make it flush with the edge . Going to make any changes today , and then add a one layer of fiberglass mat to hold the shape then pull it off the cat to bodywork on the bench . I would like to thank everyone that's fallowing my build , it's really appreciated , great to have your interest and kind comments . Cheers Phil 7 Quote
Falcata Posted November 28, 2021 Author Posted November 28, 2021 Hi everyone back with another update , had some harsh weather here in B.C. tons of rain , washing out roads and major flooding . The road to the shop was washed away , had to drive twice as fare to get there for over a week , it could have been way worse . Back to the build , got the back corners of the rear bumper cover done , and the bumper cover off to do some body work . Once that's ready I am going to mold it and make a part from it and put that on the car . Closing off the bottom Layering the bottom in with foam the lower half i did overlapping to make it easier and so there would be somewhere to glue it to . The back edges will still need to be trimmed two layers of fiberglass mat to hold its form this is where the bumper cover separates from the back fender stay tuned I will post more tomorrow , you will see it cut off and off the car !!!! 5 1 Quote
ShortPaul Posted November 28, 2021 Posted November 28, 2021 Looking really good i have missed your updates😁 Quote
The Bounty Bar Kid Posted November 29, 2021 Posted November 29, 2021 Can't wait to see the results Quote
Falcata Posted November 29, 2021 Author Posted November 29, 2021 Hi Back with more rear bumper cover updates These are the parts that will be the bottom of the fender ( quarter panel ) where the bumper cover will bolt up too . They get rounded over on the bottom side so the fiberglass can make it around the corner . ( They are taped together so the router has an edge for the guide wheel ) Here is the fender cut for the bottom piece to go in . I made this shoe for this RotoZip Router so I could radius parts in place . Here is the sharp edge on the bumper cover ( the fiberglass won't stay over that unless it was vacuumed bagged down while curing ) here is the soft edge Bumper cover off !!! next will be some stiffeners on the top inside so it can be fiberglassed and bodyworked a shot of the inside 3 Quote
The Bounty Bar Kid Posted November 29, 2021 Posted November 29, 2021 This is going to be insane! Quote
Falcata Posted November 30, 2021 Author Posted November 30, 2021 Just a bit more Stiffener on the top A couple of gussets Filled in the exhaust hole and routered the edges that's it for now Stay tuned and stay safe everyone !! 4 Quote
Falcata Posted December 18, 2021 Author Posted December 18, 2021 Hi just a quick update , not too much to see . My wife had knee replacement surgery , so i have been sticking close to home . Catching up on house maintenance and care giving ..........I guess I can add nurse to my resume lol . Back framed the rear bumper to make sure it won't pull when the fiberglass cures This also allows me to stand it up to work on Started trimming the edges , I wanted to keep them about 1/2 an inch long ( 13 mm) but there wont be enough draft to get it out of the mold. I added feet to the frame so it will be at the proper angle , same as it would be on the bench as on the car . that it for now , more before the fat guy comes down the chimney lol. Cheers 4 1 Quote
The Bounty Bar Kid Posted December 18, 2021 Posted December 18, 2021 Amazed by your talent as always 👏 Quote
Falcata Posted January 8, 2022 Author Posted January 8, 2022 (edited) Happy New Year everyone !!! Well another great start to the new year ........ more F^$%kin Covid and to top that off a @*!# load of heavy snow !!!! Which for me means shoveling and little or no access to the Falcata shop in the Forest , I have been trying to make the best of it with working on drawings for the small parts to 3D print . So here is what I do have to update , on the rear bumper . Here is what needs shoveling ...... This is how much snow we got , three times , the world is changing we never used to get snow like this in Victoria . Sorry back to the beast I like this pic , I am glad I made the rear bumper cover come off in one large piece , this makes it easier to access other stuff , like the exhaust , taillights , fuel filler , trunk latch , and suspension . I was going to add some curved out foam to the little winglets at the top , but decided to delete them , they will just add to the list of time eating stuff to bodywork . they would have gone here to help with not having to sand in a tight corner . I have a deadline to meet and need to simplify some of the parts , don't worry it will still be insane !!! So I cut the little winglets off , way faster to sand and saves time . I think it still looks hot like this . I also added a flange to the top of fender ark matting surface . this will give me a distinct line to trim the part later . Here is the passenger side next I closed off ( filled in ) the bottom corners . Well that's it for today , sorry there isn't more , waiting for the phone to ring , with the guy telling me they plowed the road into the shop . Cheers Stay Tuned and Stay Safe !!! Edited January 8, 2022 by Falcata extra pics 6 Quote
Stutopia Posted January 9, 2022 Posted January 9, 2022 Happy new year to you too mate, great to see some more shots of the work. Keep it up! Quote
Sim Posted January 10, 2022 Posted January 10, 2022 Happy New Year : ) Wow, good bit of snow there. So, stupid (maybe not so stupid) question, presumably you use all these parts to make molds and then make GRP/FRP parts from the molds? Quote
Falcata Posted January 10, 2022 Author Posted January 10, 2022 6 hours ago, Sim said: Happy New Year : ) Wow, good bit of snow there. So, stupid (maybe not so stupid) question, presumably you use all these parts to make molds and then make GRP/FRP parts from the molds? Hi Sim I don't know what GRP/FRP stands for , but yes I make the parts out of foam , wood , plastic etc then body work them to a finished state then take a mold from that part and then make a part from that mold . The parts out of the molds will be trimmed , etc then bolted onto the Zed , was hoping to have molds good enough not to have to bodywork and paint them , we will see as time is running out for me at the shop I am in. And today is another snow day !!!!! that I can't get into the shop . Thanks for your interest 2 Quote
Falcata Posted February 3, 2022 Author Posted February 3, 2022 Hi everyone it's time for an update . Been working on the beast as usual here's what I have been up too . I added some extra to the bottom where the diffuser will eventually go the inside of the other side It was no fun at all to fiberglass inside the ducts bumper cover starting to take shape Getting ready for more glass with this foam you have to glass over it before you apply any filler or when you try to sand it just tears it out in chunks . Here you can see better the pieces i added to the bottom upside down to apply filler and sand here checking to make sure everything is staying symmetrical , it not easy , so many compound curves . started filling in the fender inside lip with foam . I modified my fender roller ( it didn't reach the edge by a long shot lol ) Using it to check and ensure that both sides are the same More quality control , this is an unbelievable amount of work , I am going as fast as i can , it's just me and I have to have this finished by late spring . I need to get it done but a also don't want a pile of crap after all the effort that's gone into it so far . 2 Quote
Falcata Posted February 3, 2022 Author Posted February 3, 2022 Also did a favor for my neighbor , he is building a 1964 Ford Ranchero , small block Ford , manual trans , EFI , Modern suspension , it's going to be very sweet and super straight . He asked me to make him a sheet of fiberglass to make some inner fender covers for inside the box , these will finish off the transition between the wheel tub and the box side . I will post a couple of pic's of his car next time I tried to get them off my phone but it wouldn't load them on this site ? Cheers for now . Stay Tuned and Stay Safe !!! 3 Quote
The Bounty Bar Kid Posted February 3, 2022 Posted February 3, 2022 Looking good as usual, and whilst reading I was wondering when you were aiming to finish it then you said late spring. Can't wait to see the finished result. Quote
Falcata Posted February 4, 2022 Author Posted February 4, 2022 Got the pics of the Ranchero to Sync , so here they are . Here you can see where the gap is in the box side and the wheel arch and this is the fiberglass part that will conceal the gap , it will look decent . 3 Quote
Falcata Posted February 4, 2022 Author Posted February 4, 2022 Back to the Falcata Some more on the rear bumper cover . More quality control Compound curves ...... so much fun I decided to make the exhaust slot deeper , to give that area more strength and easier to chop the back off to make the opening . I made the mistake of putting filler on the foam edge without fiberglass first and the shape got away from me . so this will help me get it sorted out faster . This is it cut out The new part to go in , by myself it's very difficult to be on both sides to line things up and glue etc , so I had to cut the part in half . The little foam posts were to hold the gap open to glue it in place using the laser to insure it was right and checking with the template the first layer of glass , will flip it over to do the top today . It will look better if you can't see the back edge past the exhaust tip . Cheers for now , thanks for fallowing along . Stay Tuned and Stay Safe 5 Quote
Falcata Posted March 19, 2022 Author Posted March 19, 2022 (edited) Hi everyone It's time for an update !!! As I said I am going full steam ahead , so not much time for anything else but the car . a couple of reasons , 1 I want it done and 2 I am losing the Shop in the forest , possibly as soon as the end of May or sooner . So enough about that !!!! been busy . Getting the quarter panels read for foam , had a hard time finding the 2 part spray foam and it's tripled in price .... Made some protective trim for the opera window rubber so it doesn't get destroyed by sanding The line from the top of the head light ties into the feature line off the rear deck lid cutting layers of Mat to put on the quarter Edited March 19, 2022 by Falcata 9 Quote
The Bounty Bar Kid Posted March 20, 2022 Posted March 20, 2022 Looking good and looking forward to seeing it completed Quote
LRF4N Posted March 20, 2022 Posted March 20, 2022 Can see it taking shape now, a real work of art 👌🏼 2 Quote
Keyser Posted March 21, 2022 Posted March 21, 2022 Absolutely mad - I love it Keep up the good work 2 Quote
Adrian@TORQEN Posted March 21, 2022 Posted March 21, 2022 Probably one of the best Z build related threads ever. Amazing! 1 Quote
Wilster Posted March 21, 2022 Posted March 21, 2022 So many people sell a project car three quarters of the way through and all they are doing is bolting a ready made kit on and filling and spraying. this is truly awesome. I was proud of myself fixing and spraying my front bumper but now I’m going to go in a corner and sulk for a while.😁👍 2 Quote
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