80 series gullwings rear windows

[karl webster]

I know what you mean Karl, but I have had stuff made by these guys before and it has always been spot on and usually when they have said and that's for one offs. They really are just very busy and it's holiday season. Trouble is, it's like changing checkout queues at the supermarket if I try somewhere else. As soon as you do, the original queue starts to move. They did say Monday but would try for before the weekend, so I'm giving them the benefit of the doubt.

The wheel that does the squeaking is the one that gets the grease…I'm beginning to squeak…lots!! Once I get the prototype done and sorted and we're on to the actual doors then it should be ok as that will just be feeding the machine once it's set.

Bear with me fellas…keep those fingers crossed and I hope to have some good news for you soon.

I didn't actually mean the guys you have on this. I just meant companies in general.

 

[StarCruiser]

No worries Karl, I know what you meant. We WILL get there, I just feel it's a good thing to keep everyone updated.

 

[Chas]

We WILL get there, I just feel it's a good thing to keep everyone updated.

 

[karl webster]

 

[StarCruiser]

Phoned the sheet metal shop this morning and now told this job is up next, possibly this PM.

The irony is I now know what's been holding them up as a pal of mine was having some control panels made at the same place. Fortunately they are now finished so…well, just keep those fingers crossed for a little bit longer and we might see a prototype this week.

Then…they are going away next week for 3 weeks shutdown[emoji33][emoji33][emoji33][emoji27][emoji32][emoji30]

So once I've got the prototype mocked up I will need to get some idea of numbers to go ahead. I will have a price by then and will make some extras. But if I can get them cut out before they go away then we should have a chance of getting them done once I get a hold of them. Then I can at least try to get them to you for your planned trips.

Watch this space as they say…

 

[Chris]

Watching ......

I'm planning what to do with the space once I can access it.

 

[StarCruiser]

Ok folks it the post we've all been waiting for…

The prototypes were delivered today…and…I got the drawings almost right !!!![emoji39]

So, spent the rest of the day, about 5 hrs, measuring and adjusting the drawing.

Good news is that my drawing went straight on the machine, no reported problems![emoji41]

Here's what they look like so far with a coat of grey primer to keep the 1mm steel clean:-

Not quite right and just stuck on with some foam spacer and adhesive Velcro.



I was really pleased with how the frame turned out. Apart from one corner it was within 1mm or so of the template.



Catches dropped in to give an idea.



My only concern is getting the door to open up inside the window frame at the top without fouling. I'm going to have to mock this up and test it tomorrow.

At least I've got something to get my teeth into now and not waiting on a call.

 

[Chris]

Hell yes.

 

[Chas]

Dogs danglies.

 

[cmcmill01]

Good work


Sent from my iPad using Tapatalk

 

[StarCruiser]

Thanks guys!![emoji4][emoji4]

 

[StarCruiser]

Ok, today started with lots of hope and enthusiasm…now? Well now I'm a bit deflated. Not too much. Just a bit.

So, I got all the alterations cut out of the sheet and held it to the window on the Velcro and it looked OK.


So I bit the bullet and started taking the glass out using a paint scraper covered in duct tape and some 5mm packers, which were better than the scraper.


Once out, I fitted the frame, and thought… that looks pretty good:…

Next was to mark up the hinges and get them welded on after checking the C5 latches worked ok, which they did

Fitted the door and hinges next. Then my fears are confirmed, the door fouls the bodywork when opened. [emoji22][emoji22][emoji22][emoji36][emoji21]

So, the only option is to do a couple of cut aways. …

Which made the whole thing look a pigs ear (in my opinion). Time for some head scratching.…unless, that is, anyone thinks they will look ok to them with cut outs at the top? I've got to say I'm not happy with the look as I was hoping for better. The only solution I have come up with is to move the hinges down and have a strip of infill across the top… and all this with the sheet metal shop going away for three weeks.!!

In the meantime I decided to use up what black spray paint I have and spray it black to see what the final effect would be…except I didn't have enough paint so you'll have to excuse the appalling paint job.







And excuse the improvised lid stay…


Like my school report used to say…could do better[emoji20][emoji20][emoji20][emoji22]

 

[Chris]

Sorry but I think the issue here is that you have tried to make the flap too big. My plan (in my head) was to make a frame the same exactly as the glass, cut a hole in it leaving at least 30 mm all the way round then make the flap to overlap the frame by only 15 mm or so. The frame bit looks perfect from here. Just can't see why you have made the flap bigger by so much.

 

[stumog]

My idea would have been to make the frame like you have done. Then have the flap part the same size as the hole. This would also half your metal cost. The have a frame of angle bonded to the frame to mount your seal to.
Good luck Stu

 

[fbnss]

Nearly there.Would a rubber strip or something along the top edge of the opening not cover the rough edges as it were?

 

[StarCruiser]

Thanks all.

Chris, my plan was to make the hatch door a flush part to the rest of the bodywork so that the look was rather like a standard car door. You are right in that it is too big.

Stu, what you are suggesting, with laser or water jet cutting would mean only one piece of metal, however punching out (as this is) takes away too much metal and would involve two stampings. However your suggestion is something I am considering.

Nick, this is sort of where I am at the moment, however I was thinking of a metal cover or infill strip at the top.

Suffice to say that you all share my dislike for the current look at the top re cut outs.

This is, after all, the first time I have mocked up hinges mark two.

Still head scratching.

 

[Chris]

Dislike is a strong word. More that we share your disappointment at Mk 1 version

 

[stumog]

My way is how all the others have been made that I have seen. Fair play for having ago. This is what more people should do. Put your stuff up as more eyes are always better then the ones you or I have.
Stu

 

[Iwan]

Don't get dismayed mate. . Your doing a sterling effort there man.. maybe you could reduce the "flap" all around the perimeter to account for the catching on the top edge corners. . Then you still retain the overall constant shape. . Good work and arrangement.. All the best iwan

 

[Chris]

This is what says it for me ....
There's a seal in both the inner frame AND outer flap.