The loooonnng term EK 2 door project

[Errol62]

Easy done mate


FB ute fixer upper, EK van on rotisserie

[Blacky]

Todays effort - roof skin removed from frame , slid back to effectively pancake the roof , frame now lines up with both A and B pillars




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[EK283]

Blacky thats looking great and being done correctly as well.

Have you got the courage to go pillarless ?

great work, hats off to your metal chopper.

Greg

[Blacky]

Blacky thats looking great and being done correctly as well.

Have you got the courage to go pillarless ?

great work, hats off to your metal chopper.

Greg

Dont want to go pillarless mate, this has been in my head for 40 years and its always been pillared

[Blacky]

Tonight’s homework was to try and make a timber dummy windscreen that can be trimmed to see how to build the car so a standard screen can be used to cut down rather than go through the considerable expense of having a custom one made
Started by making a central “spine” on an old toughened windscreen that was floating around in EKMart

Used my McGyvered up marking pen to mark the shape required


Then did a bit of fine tuning to get the thing to sit nice and cut some cross braces to help it keep its shape - hopefully


Then hit the MDF with some hot water and clamped it to the screen and will let it set overnight and find out tomorrow if it’s going to work


Talking to Mr Smooth Customs and he advised me to make a fibreglass screen but I have never used fibreglass before so thought I would give this a try first. Next week may be a crash course in fibreglassing


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[Errol62]

Polyester resin and methyl ethyl ketone peroxide, mmmmm.......

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[Blacky]

Well I buggered up windscreen #1
Marked it out like so -


Cut it out and laid it over the glass like so -


Bugger
Onto Mk2



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[In the Shed]

Here is roof for ya

https://www.gumtree.com.au/s-ad/west-sw ... 1323000137

[Blacky]

Here is roof for ya

https://www.gumtree.com.au/s-ad/west-sw ... 1323000137

He and I don’t get on

[EK283]

A trap for the young players, always longer on the outside.

Normally, its make things 3 times but i can see your on a winner, mark 2.

Greg

[Blacky]

Windscreen #2 is a winner




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[Blacky]

More progress on the frame today - started from scratch with the section between B and C pillars






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[Blacky]

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[Errol62]

TISM!


FB ute fixer upper, EK van on rotisserie

[Blacky]

Well the MDF windscreen worked a treat , it fits with some judicious trimming across the top of course and around the bottom corners to lay it back.
Will need to widen the roof across the top to suit it though, about a 1/2” filler piece in the middle of the roof ought to do it



Fits nicely now




Next step is to use this as a template and cut down a real windscreen to finalise the shape of the opening


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