Hand Formed Aluminium Body

[John Bonnett]

Thank you all of you for your kind words which are very welcome and always give a boost to the old motivation particularly at a time of the year when energy levels can be on the low side.

I'm taking a break from panel work and will be concentrating on the bonnet supporting frame and the hinges. I have a very high regard for the young Canadian who is showcasing his GT6 restomod on his Youtube channel and I'm hoping to copy his design for the bonnet hinge arrangement. I have sourced the same hinges which are double acting, very compact and light being made from aluminium. The clever thing about his installation is that it prevents bonnet twist as both hinges operate as one thanks to the interconnecting round tube. The clever bit is mounting them in the optimum position so that the bonnet opens fully. I'll let you know how it goes.

[Hamish]

I have been looking up the Triumph SLR  and what TR Enterprises are doing with their recreations. 
i found this blog that reminded me of all your hard work John especially the buck ? Wooden form. 
https://forum.retro-rides.org/thread/204081/1962-triumph-tr4-slr

[Nick Jones]

21 hours ago, John Bonnett said:

have a very high regard for the young Canadian who is showcasing his GT6 restomod on his Youtube channel and I'm hoping to copy his design for the bonnet hinge arrangement

Me too. Good plan 

[John Bonnett]

Thank you the link Hamish. It must be a huge advantage to be able to scan a car and then feed the results into a CNC router to produce the egg box buck. A costly exercise nonetheless but it has to be absolutely accurate. RetroPower are doing the same thing at the moment on the rear bodywork of an E Type. Disappointingly, they are farming out the panel work to a specialist rather than doing it in-house, something I would have thought well within the capabilities of Stu and Tom, and which would have been of great interest to the majority of their YouTube viewers.

[BiTurbo228]

On 3/28/2024 at 12:52 PM, John Bonnett said:

Thank you all of you for your kind words which are very welcome and always give a boost to the old motivation particularly at a time of the year when energy levels can be on the low side.

I'm taking a break from panel work and will be concentrating on the bonnet supporting frame and the hinges. I have a very high regard for the young Canadian who is showcasing his GT6 restomod on his Youtube channel and I'm hoping to copy his design for the bonnet hinge arrangement. I have sourced the same hinges which are double acting, very compact and light being made from aluminium. The clever thing about his installation is that it prevents bonnet twist as both hinges operate as one thanks to the interconnecting round tube. The clever bit is mounting them in the optimum position so that the bonnet opens fully. I'll let you know how it goes.

Haha interesting to see this catching on as it was me that came up with it! The video clip at 1:19 is yours truly some 6 years ago.

I do think he's done it much better though (unsurprisingly considering the quality of his work). Both tying them together, and angling the hinges upwards in their resting position which helps lift them over the bumper rather then pushing the bonnet through it.

Really I'm just chuffed I've helped contribute something to Triumph posterity 

[John Bonnett]

22 hours ago, BiTurbo228 said:

Haha interesting to see this catching on as it was me that came up with it! The video clip at 1:19 is yours truly some 6 years ago.

I do think he's done it much better though (unsurprisingly considering the quality of his work). Both tying them together, and angling the hinges upwards in their resting position which helps lift them over the bumper rather then pushing the bonnet through it.

Really I'm just chuffed I've helped contribute something to Triumph posterity 

Yes it was your idea and a great one at that. He did acknowledge you in an earlier video if I remember correctly. The round tube and box section have just arrived and I'm looking forward to getting started on the hinges before too long.

[John Bonnett]

Sadly, I could make the Bemer hinges work for me. No matter in what position I placed them, they clashed with either the grilled frame or the chassis on opening. It was a shame because they are nice hinges, light and well thought out and I had spent a lot of hours working on them before deciding they had no future on my car.

So, I designed my own which have actually worked out very nicely, fully adjustable in all three directions and allow all the movement we need.

Along with the bonnet frame which supports the skin which is underway, parallel work is also taking place on the interior with the Dynamat going in and the mountings for the interior light and the sun visors.

[John Bonnett]

I see the last update was back in the middle of last year so this should bring things up to the minute but while there has been some progress, not as much as I would liked and expected in that time. In fairness, there have been one or two setbacks which slowed things down and sapped some enthusiasm until everything was rectified and back on course.

A couple of examples. I intended the bonnet to kick up and shroud the wipers and spent a chunk of time forming the section out of steel. Photo 1. I didn't like it so binned that idea in favour of keeping the bonnet flat and close to the scuttle.

The second alteration and much more major was reshaping the profile of the body at the B post. I had done it like this for a good reason but for the life of me I cannot remember  what it was but it couldn't possibly flow into the front without a very strangely shaped door to transition the shapes front to back. Photo 2 Major surgery was needed but once done, the problem was solved. Photos 3, 4 & 5

Next up was fabricating the door frames which was a challenging exercise. There is so much going on in a door that isn't readily apparent, or wasn't to me, until I embarked on the build. The frames are made using 16mm round tube bent to the desired profile and 18swg steel L section shrunk and stretched to suit. Time consuming but straightforward. The problem came with the placement of the hinges. I'm using Skoda Octavia mk2 door hinges and i should have take a more careful look at how they are fitted. Photo 6. I was pleased with the fixings but the geometry brought the front edge of the door forward by 10 or 15mms which would have made the panel gap ridiculous. So, the hinges needed to be repositioned as far outboard as possible. Photo 7 This solved the issue and a 5mm gap is no problem. Photo 8

There is a bridging section of fixed bodywork between the door and the bonnet the frame of which is formed from the steel L section the same as used on the doors. Photo 9

Photo 10 brings us up to date with both doors finished to the same level.

 

 

[Hamish]

Loving the attention to detail John. So pleased this is still progressing keep us updated as you go on. 
very much respect to you for your skills.

[RedRooster]

You're not the only one to be caught in the moment, I've nailed my most spectacular failures to the garage roof to remind me to think first, twice. 

[Nick Jones]

Doors and A pillar are looking really good John. 
 

Making it up as you go along ( no disrespect intended, quite the opposite!) is hard as the law (and small gods) of unintended consequences is (and are) complete bastards….

[John Bonnett]

Thank you all for your kind words and encouragement. My friend Derek who is a world class coach builder has been keeping me on the right track and it is thanks to his advice that the bodywork issue is now resolved. Derek is going to make the bonnet because handling such a large panel is beyond my skill level. Once the bonnet is welded to the wings and the valence it's going to be a very large structure and very unwieldy.

[John Bonnett]

It has taken from January to now to complete the work ready for Derek and yesterday, it was collected. Quite a momentous moment and it was a nice experience to drive it out of the workshop up the lane to the waiting trailer.

 

[Nick Jones]

A landmark John….. but how are you going to amuse yourself without it?

[John Bonnett]

10 hours ago, Nick Jones said:

A landmark John….. but how are you going to amuse yourself without it?

A very good question Nick. I’m feeling quite bereft with no project and an empty workshop. Suggestions on a postcard please. 

[Hamish]

If only you were closer John I have an engine build and/or some Alvis wiring to fathom

[John Bonnett]

I'm sure we are all in the same boat, strapped for cash, but in the unlikely event that some kind souls would like help me finance the professional work that is outside my ability and has to be done,  I've set up a crowdfunding appeal. I'm already half way to  the target so anything, no matter how small, would be very welcome, thank you.

https://www.crowdfunder.co.uk/p/invitation-to-help-me-raise-funds/backers#start

The two photos show the car sitting in Derek's workshop ready for work on the front end to commence.

 

[John Bonnett]

Time for an update. Derek has had the car for four weeks now and he's made really good progress, first carrying out remedial work on the rear quarter panels near the B post where there was an alignment problem and then getting down to panelling.

I won't say any more and will just let the photographs tell the story.

 

[Nick Jones]

Wow! That’s coming on  - the lines are starting to emerge 🙂

[RogerH]

That door looks very impressive.  The plain panel adds to its purpose. 

I can't wait to see the door handle

The boy did good.

 

Roger

[Escadrille Ecosse]

Most impressive!

[Mark]

Very nice work. Really coming together.

[John I]

That’s looking amazing, finished article worthy of “ bond James Bond”

[JohnD]

Indeed!  But I ask Q, is it invisible?

[John Bonnett]

Thank you all for your very kind words. I never like to wish my time away but I can't wait for Derek's Friday updates.