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Re-body My Zed


Falcata
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On 24/10/2021 at 08:56, davey_83 said:

Very nice pictures, will you be doing any underbody aero? 

Hi 

As far as underbody Aero go's , just the Splitter on the front and the diffuser at the back , and of course the front fender vents to let the air escape from the render wells .

I have to leave something alone or I will never get this beast done LOL .

( It's bad enough my buddies are saying no more changes allowed just get it done already )

Thanks for tagging along 

Cheers

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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 .

 

 

IMG_20211026_170331256.jpg.b54f7bec516a9ba1cfd54c35f0df47c9.jpg

 

IMG_20211026_170419355.jpg.600cd5fdec4051ef0ee89dc29e3fc159.jpg

 

IMG_20211026_170443795.jpg.d2e50a48914005acadd3158ecfdc7574.jpg

 

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 .

IMG_20211026_171131156.jpg.2d6746ae0bdb5cd098eb5f48e0b5a3ce.jpg

 

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

 

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  • 1 month later...

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 .

IMG_20211102_172432497.jpg.8cab1809d9215266369b66ac7b350ad9.jpg

 

Closing off the bottom

IMG_20211110_122843840.jpg.1662bd7b846ae752b53b43207763433b.jpg

 

IMG_20211110_132120893.jpg.f8f5e45e2430928df692d128e4f532fc.jpg

 

IMG_20211118_142212792.jpg.d427081239de21f0c19ae44989c38ab5.jpg

 

Layering the bottom in with foam

IMG_20211118_161130429.jpg.11e20c745e38738ba458e6b9a5386917.jpg

 

IMG_20211118_161216621.jpg.274a5f578e3c191404ad0c1d6a94bb10.jpg

 

IMG_20211121_114318520.jpg.d9026df2d841d803d0b1e7ead2a96687.jpg

 

the lower half i did overlapping to make it easier and so there would be somewhere to glue it to .

IMG_20211121_134426337.jpg.e37629c81d0f29acb09ab667b631b7d3.jpg

 

IMG_20211121_134512098.jpg.c36aea09a30c438d1581d9c9514ff235.jpg

 

The back edges will still need to be trimmed 

IMG_20211121_160724513.jpg.cb3619c8d759485801ba0cfaf523ff8a.jpg

 

IMG_20211121_160736678.jpg.4592d42061f23b298ec301572e694bcc.jpg

 

IMG_20211122_141543284.jpg.8b0df084199a604442900f36edb7a1b3.jpg

 

IMG_20211122_155732802.jpg.57ae37847be7a481a944ab787f29d786.jpg

 

two layers of fiberglass mat to hold its form

 

IMG_20211122_155836217.jpg.052fa51e4c1544ef7bc4b651107c334e.jpg

 

IMG_20211122_155919449.jpg.4bd5f7a2954db37ed4183ff030b0152c.jpg

 

IMG_20211122_160750723.jpg.6a72c4b834d1761ea87e994c88900529.jpg

 

this is where the bumper cover separates from the back fender

IMG_20211123_125243045.jpg.aa911d19ee4da0c19d274452ba83f9e6.jpg

 

stay tuned I will post more tomorrow  , you will see it cut off and off the car !!!!

 

 

 

 

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Hi

Back with more rear bumper cover updates

 

IMG_20211126_154127849.jpg.735bb0380e014a0ab90ddecd176dbfcd.jpg

 

These are the parts that will be the bottom of the fender ( quarter panel ) where the bumper cover will bolt up too .

IMG_20211126_155717099.jpg.984a3b57b4c95049c52af430e7ad5b2b.jpg

 

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 )

 

IMG_20211126_165944584.jpg.6ab23e04c51b4797fe6fbfbaaaacafe2.jpg

 

Here is the fender cut for the bottom piece to go in .

 

IMG_20211126_172626745.jpg.b722a171e1d6ac8e7f8bbbbfa0598ff8.jpg

 

IMG_20211127_125447555.jpg.b22130cee709c8f1a19e4485782cf9c0.jpg

 

I made this shoe for this RotoZip Router so I could radius parts in place .

 

IMG_20211127_130740651.jpg.fb1dd64bf9b55ba332efbe277a382fb0.jpg

 

Here is the sharp edge on the bumper cover ( the fiberglass won't stay over that unless it was vacuumed bagged down while curing )

IMG_20211127_131249868.jpg.c411f57827336e2ee2d941d1534fd2bb.jpg

 

here is the soft edge 

IMG_20211127_153739180.jpg.e904f2093da06489f931cfafd16f3d53.jpg

 

Bumper cover off !!!

IMG_20211127_153851733.jpg.78dc10aeaebfd4c9a26378328eba5b9a.jpg

 

next will be some stiffeners on the top inside so it can be fiberglassed and bodyworked 

IMG_20211127_153925460.jpg.720c55226348efdb99352850036eefbf.jpg

 

a shot of the inside 

 

IMG_20211127_154030131.jpg.55dc635fe7825dbe68b9ab5dc1a9e0c9.jpg

 

IMG_20211127_154620972.jpg.5ece0786123be7f2cb6e84d686331a02.jpg

 

IMG_20211127_161210101.jpg.4957763f58f7569ff0ddce711ee047d7.jpg

 

 

 

IMG_20211127_153823941.jpg

IMG_20211127_155054021.jpg

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  • 3 weeks later...

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 .

IMG_20211212_135533276.jpg.9a5e1da4c527df7c58ad8800119e9e6e.jpg

 

IMG_20211212_135706692.jpg.c099190c58e24284aa8ec4ff1ec0a9a2.jpg

 

Back framed the rear bumper to make sure it won't pull when the fiberglass cures 

 

IMG_20211212_141900206.jpg.6103fb56bde53ce4cef0400786afe54d.jpg

  

This also allows me to stand it up to work on 

 

IMG_20211213_125700187.jpg.57667e8a17aa695b86e73517b325bab5.jpg

 

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.

IMG_20211216_145010518.jpg.e694973cda3c298e1104c62d86200754.jpg

 

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 .

 

IMG_20211216_145030183.jpg.10616c01f4794c03013e2abc85d7cf40.jpg

 

IMG_20211216_145124873.jpg.7602101c47b4df40e9087608a8c2ffc7.jpg

 

IMG_20211216_144959249.jpg.8322dbf2270e2d13c831e7ba67f5e41f.jpg

 

that it for now , more before the fat guy comes down the chimney lol.

Cheers 

 

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  • 3 weeks later...
Posted (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 .

IMG_20211226_134945449.jpg.7971a8d0e3c1c081b08a665050d39ba0.jpg

 

Here is what needs shoveling ...... 

 

IMG_20211230_101318445.jpg.fb4315f6224d4b8a0c2a2f52b414efac.jpg

 

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 

IMG_20211210_135126651.jpg.ba72c536c687ee5e8df1113a274a3b8c.jpg

 

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 .

IMG_20220104_151426042.jpg.12f8648910540d41110085b994299f89.jpg

 

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 .

IMG_20220104_151417115.jpg.ec23a5fbe68a1ac799c225d735d5b66b.jpg

 

they would have gone here to help with not having to sand in a tight corner .

IMG_20220104_151407535.jpg.9bdcac41f9155e58c5f44e733b31e067.jpg

 

I have a deadline to meet and need to simplify some of the parts , don't worry it will still be insane !!!

IMG_20220104_170017714.jpg.5f13572c94c5815d50c0600af433e274.jpg

 

So I cut the little winglets off , way faster to sand and saves time . I think it still looks hot like this .

IMG_20220104_170049424.jpg.3407c463264e35e911f0ead94b554a9b.jpg

 

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 .

 

IMG_20220105_151724873.jpg.0be0dabb1b5e3c44be3b3f07090bcad2.jpg

 

IMG_20220105_151807712.jpg.faaeecabfda73054ab77f2a12a4836f4.jpg

Here is the passenger side

 

 next I closed off ( filled in ) the bottom corners .

IMG_20220105_151659775.jpg.053f00a2a513eda12334d3ff923673c2.jpg

IMG_20220105_171237990.jpg.9c76d1bd42c3bcaf342a82a4650697d0.jpg

 

IMG_20220105_171258133.jpg.7bcd895e49802808624762f45d40b962.jpg

 

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 .

 

IMG_20211210_135314182.jpg.f09d9ce11a6a236b6eb2866eec6f384b.jpg

 

 

 

Cheers

Stay Tuned and Stay Safe !!!

 

 

 

 

 

 

 

 

 

IMG_20220104_170037216.jpg

IMG_20220105_151751083.jpg

Edited by Falcata
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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?

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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   

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  • 4 weeks later...

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 

 

IMG_20220113_162525327.jpg.5ff08ea12aff18062c97404725d573ee.jpg

 

the inside of the other side

IMG_20220113_162552359.jpg.721e7b368f97eb7b8d45d340d7f10958.jpg

IMG_20220113_162605897.jpg.2ac49f7c82c5e9b07d3ddb88c68fe062.jpg

 

It was no fun at all to fiberglass inside the ducts

 

IMG_20220113_171753748.jpg.c959e34de6fb19c42ccce304ad520f41.jpg

 

bumper cover starting to take shape

 

IMG_20220114_160508511.jpg.03b66a496e710f82da29ed4579906e45.jpg

Getting ready for more glass

IMG_20220115_123429784.jpg.79905cbdf2dfcff7e75b8714a2cf710d.jpg

 

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 .

IMG_20220115_123458537.jpg.87c76bb819563067a63f0202846c8d90.jpg

 

Here you can see better the pieces i added to the bottom 

IMG_20220115_123531263.jpg.7e2f409472fbf592d5767ec16d65c7c7.jpg

IMG_20220116_142524546.jpg.fe7da37de17342448452c47cc1c45bb0.jpg

 

upside down to apply filler and sand 

 

here checking to make sure everything is staying symmetrical , it not easy , so many compound curves .IMG_20220119_163010387.jpg.c3c8bf2aef2d4a9c64cd3d60e25fa7a9.jpg 

 

IMG_20220119_162931543.jpg.5238d706dc8b1fa2affdb3c52c673f05.jpg

 

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 

 

IMG_20220120_115342656.jpg.d82bc74c196aa57a791a27f16d82f407.jpg

 

IMG_20220122_131144822.jpg.d86a9a7679196057fa237d7dfdb6e9e2.jpg

 

IMG_20220124_152749922.jpg.4d648cb25f8bedf3c1278e3b5a00b856.jpg

 

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  .

 

IMG_20220126_124848809.jpg.15dac75d5e69067ce6283d9b24f8fbeb.jpg

 

 

 

IMG_20220126_124904523.jpg

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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 ?

IMG_20220128_104410561.jpg.1983f7788efebe903b799556f1c2d518.jpg

 

IMG_20220128_104422248.jpg.064dbd70bb4fd93743bda9421893485b.jpg

 

IMG_20220129_103221530.jpg.c8968f8e06bace6c1c9a334b3d38039e.jpg

 

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IMG_20220129_111249418.jpg.8282bb921b069ab9fbd7bbe58be1ca9d.jpg

 

Cheers for now .

Stay Tuned and Stay Safe !!!

 

 

 

 

 

IMG_20220129_111249418.jpg

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Got the pics of the Ranchero to Sync , so here they are .

 

IMG_20220204_083317.jpg.77a05331a73683c48ed50817e3c4ce5c.jpg

 

Here you can see where the gap is in the box side and the wheel arch 

 

IMG_20220204_083456.jpg.1e13c7dd600d915783f9228efa73a920.jpg

 

and this is the fiberglass part that will conceal the gap , it will look decent .

IMG_20220204_083127.jpg.619a0c406764f3a2aacb3b11e3a5c022.jpg 

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Back to the Falcata 

Some more on the rear bumper cover .

More quality control 

 

IMG_20220129_135458605.jpg.a4beb9b9498f97b642175aec745cb2f2.jpg

 

Compound curves ...... so much fun 

IMG_20220129_155723242.jpg.e3f7106fe2611c2ff6a0268504502f6a.jpg

 

IMG_20220129_165113942.jpg.e2cb732c696698d5f57ed0470f813eaf.jpg

 

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 .

 

IMG_20220201_154016952.jpg.4c632c86d3b77de3b2f7f789a228d58a.jpg

 

This is it cut out

 

IMG_20220202_114208897.jpg.41ba18d509d586d1d1c3343bdc2e52ad.jpg

 

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

IMG_20220202_114353507.jpg.57f8f173ed36d230bb50f44c46dace20.jpg

 

IMG_20220202_115920283.jpg.00988da538d8fb3763989ec73b18e0d8.jpg

 

and checking with the template

 

IMG_20220202_132917013.jpg.572fe1040644afadc681560c36a959ca.jpg

 

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 

 

 

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  • 1 month later...
Posted (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 ....

 

IMG_20220227_113146711.jpg.0d85c40ed4534086d4f31fb5734be1d2.jpg

 

IMG_20220227_113133184.jpg.ab8a1910fa790cfaee7f3f4e7e79eb90.jpg

 

Made some protective trim for the opera window rubber so it doesn't get destroyed by sanding

 

IMG_20220228_132457506.jpg.5abb16fd9f8cd47fa5fce8d7a7b40fb2.jpg

 

IMG_20220228_133054401.jpg.c558832bec678781742a5f5aa96b7fff.jpg

 

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IMG_20220311_120945542.jpg.05d03aef42731b4c1e3e2a6f117514f6.jpg

 

The line from the top of the head light ties into the feature line off the rear deck lid 

 

IMG_20220311_120958850.jpg.4f77243db6dacd8a87c3de414f784d62.jpg

 

IMG_20220311_153914247.jpg.36c3180475033e903ae889e483f87f46.jpg

 

IMG_20220311_164122677.jpg.6cf79163b2cae475bed64d00a1af89cb.jpg

 

IMG_20220312_170618555.jpg.03122a3306d2fdbcdaafd0b39cf77852.jpg

 

IMG_20220312_171047277.jpg.63dc7bdd2a9b7d30608b231fb77918a7.jpg

 

IMG_20220313_155100098.jpg.589df96acd5476876c78bdd66c30154c.jpg

 

IMG_20220317_170726836.jpg.d14bd913da128e05423a5b8abcd1f728.jpg

 

IMG_20220317_173039810.jpg.5dd162080ed9b4fdbdd6d59a12d8692a.jpg

 cutting layers of Mat to put on the quarter

IMG_20220318_114532342.jpg.abd53a426d9f741dcab2491f48ea07cc.jpg

 

IMG_20220318_122916054.jpg.991d48bc59d6b828eb9d584eb745dd6b.jpg

 

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IMG_20220318_143604738.jpg.88e0f523c5f40f52856d342f75f805af.jpg

 

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IMG_20220319_124624561.jpg.d6652749c69155d6c6d792b168536cca.jpg

 

IMG_20220319_124834776.jpg.6d52fb329291e189d13e9a61032594fa.jpg

 

 

 

 

 

 

 

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Edited by Falcata
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