Post by koffinbuilder64 on Apr 27, 2013 22:12:15 GMT -6
Hey Guys!! I know its been a while, but here is the 2nd part of the roof construction. If you recall, this is where we left off:
Notice the upward angle of the roof on the 2nd pic, that was the result of getting the curve & angles I wanted for the rear window area. I decided to make a horizontal cut all the way across at the top edge of the r. window & remove the entire top & make a 'pie' cut at the front of the 'c' pillers to remove that upward angle:
After removing 3/16" from the 'c' pillars, I drilled a couple of shallow holes in the 'c' pillers & the corresponding top to allow short alignment pins to be installed:
Sorry about the fuzziness of that last pic, sometimes the old camera has a mind of its own!. OK, next was the fun part of laying out the rest of the roof:
Using plastic-coated wire, the outer edge was made with the help of a cardboard template (from a discarded pizza box):
Notice also that the 'curve' was made by using a large plastic tube taped to the bench about 1/3 the way from the front edge. Next, I tackled the oval shaped tubing at the front corners of the roof (I have heard that Mr. Stucky used exhaust tubing for this to add strength, but who knows???) My first attempt (after drawing a template) was out of thin plastic, But, there was no way it would work:
2nd attempt yielded much better results, aluminum tubing! It was some kinda fun turning round tubing oval!!:
And here they are installed:
Next, the thick edge where the fabric meets the metal (on the 1:1) was made from thick stock:
The holes you see are for more plastic-coated wire to be used as a side-to-side bracing. Here they are installed:
Next will be the installation of curved plastic along the sides, that is what the pieces of tubing over thick wire along the middle of the assembly is for. But, first, I HAD to check my work by placing the roof on the car, ENJOY!! More soon! ;D:
Notice the upward angle of the roof on the 2nd pic, that was the result of getting the curve & angles I wanted for the rear window area. I decided to make a horizontal cut all the way across at the top edge of the r. window & remove the entire top & make a 'pie' cut at the front of the 'c' pillers to remove that upward angle:
After removing 3/16" from the 'c' pillars, I drilled a couple of shallow holes in the 'c' pillers & the corresponding top to allow short alignment pins to be installed:
Sorry about the fuzziness of that last pic, sometimes the old camera has a mind of its own!. OK, next was the fun part of laying out the rest of the roof:
Using plastic-coated wire, the outer edge was made with the help of a cardboard template (from a discarded pizza box):
Notice also that the 'curve' was made by using a large plastic tube taped to the bench about 1/3 the way from the front edge. Next, I tackled the oval shaped tubing at the front corners of the roof (I have heard that Mr. Stucky used exhaust tubing for this to add strength, but who knows???) My first attempt (after drawing a template) was out of thin plastic, But, there was no way it would work:
2nd attempt yielded much better results, aluminum tubing! It was some kinda fun turning round tubing oval!!:
And here they are installed:
Next, the thick edge where the fabric meets the metal (on the 1:1) was made from thick stock:
The holes you see are for more plastic-coated wire to be used as a side-to-side bracing. Here they are installed:
Next will be the installation of curved plastic along the sides, that is what the pieces of tubing over thick wire along the middle of the assembly is for. But, first, I HAD to check my work by placing the roof on the car, ENJOY!! More soon! ;D:
( I haven't yet). Ya, she gives me a chill too!! ;D 
