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.......................................--- Building the Body ---
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The tin work has started! Of course I haven't even started on the back half of the car yet.
I was going to run these pieces up to a fabricating shop and have them sheared and rolled until I checked my wallet. I decided to run up to Harbor Freight and buy a $30 air nibbler instead and found some 2" pipe in my assorted iron pile. That took care of the cut and roll. It took 3 days to rough out 5 pieces and they aren't as nice as they make with a roll a power shear but they are going to do.
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This is the back end of the front panel. I've decided to use SS 1/4-20 socket /flat head screws on the body panels. It requires a .090 back up strip that is chamfered when it is used with a tapped mounting strap that is welded to the frame. The panels that are removed between each run will have dzus fasteners. The socket size is the same size as the button screws that are used elsewhere. I have a small battery operated wrench that can be used when taking panels off.
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This is how I've been bending the panels. The rolls shown here are 2 1/2 " X .250 DOM. I have a 2 'X 1/4 DOM that I use for other radii and as you can see they don't roll very good. I cut them 52" long so could make a 4' adjustable roller (later).
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I have the canopy roughed out and am working on the inner structure that will allow the whole thing to tip up from the back. I am probably going to cut out the hole for the windshield after I use it for a form for shaping. I tried to keep it a simple bend but ended out with a little compound bend at the front. I plan on covering the aluminum with flannel and laying the polycarbonate over it after its been heated. I haven't decided on the thickness yet, but I'm probably going to go with 1/8" unless I hear different thoughts. What do you think?
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