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Thanks for the kind words guys, glad you like it.
A bit more progress today, I have made the side windows and the angle iron frames for the top of the windscreen - I bent the radius around a suitable sized pulley using lots of heat.
I have also started on the most difficult panel, the front roof section - this has compound curves to be fabricated, again I've found hammering it around the domed head of a nitrogen gas bottle seems to be about the right profile.
Finished the slam plate, had to straighten the bumper brackets and make new bumper to ensure everything lined up correctly first.
Also been making new fuel tank - I know many people don't like it inside the cabin so I will cut the floor round it and make a partition wall so it is sealed in - any leaks would then be to outside. I have had to make it narrower to be able to do that but it is taller and longer so still holds about 10 gallons which should be enough.
I have got the fuel tank sealed off now and the new rear panel is in, time to start the bodywork at the front. I made a joggling jig for the press brake and used it to do the step down on the new scuttle panel, I'm now sorting new bonnet panels - not sure what to do about the louver's - it always distorts the panel when you try and press them into a flat sheet so I may cut out the old ones and rivet them in.
Old louver's straightened out ok so took your advice and fitted them to new bonnet panel - I put them on top so it looks like it's supposed to to be that way, as you said.
not seen those, presumably they have a nut on the back and there is enough grip from the serrations under the flange to nip them up. I used soft aluminium countersunk rivets which only need a couple of taps with a small hammer to secure them and the heads can easily be filed/sanded flush.
I do a lot of sailing and have always been a bit wary of stainless and aluminium - I use chromate paste to isolate any contact between the two or you get loads of corrosion but perhaps on dry land it is not so much of an issue?
Yep, rubber tape between the alu and the steel frame, chromate paste and paint are in the plan. Idaho treating the roads with calcium chloride is a real problem.
Bonnet stay and gearbox cover today - I've modified the gearbox cover so that it will take a VW Golf gear stick boot - look a lot better than the standard bug one.
Slow progress now were on to shot blasting and painting, so far only managed back door frame and new slam plate and bumper bar. Also made new door skin and fixed the handle lock - its a vintage ford pop handle for some reason but I managed to find a new barrel on e-bay for a ford Anglia that was similar and re-built my old lock with the new tumblers and springs so it would fit the new keys.