Method to My Madness

Posted in Skins on July 2nd, 2008 by Samurai

OK, so I am working on the skins at the moment. There really is a method to my madness. The first thing is to cut the inner rear door before all the panel are removed. This gives the skins a more rigid structure so the skins don’t get a bent out of shape. After the inner door is cut and double checked, the inner panels are removed. I then removed the outer panels and JB Welded the inner and outer doors and panels together. I fit the doors and panels to the skins while the skins are clamped to the frame. This gives the correct curve the panels and doors. If you have handled the inner and outer skins for a while, it is amazing how rigid they get when glued together.

With the panels JB Welded together I used them on the rear door to make sure it was at the correct curvature.

So my steps to forming and attaching the skins were:

!) Remove the outer panels.
2) Cut the Rear Door
3) Remove the inner panels.
4) Clamp the skins back on the frame
5) JB Weld the doors together using the frame and skins to make sure the doors keep their curve
6) Super 77 the skins and door together, using the frame again as a guide.
7) Since the skins and door are still flexible, now use the doors and panels on the skins to shape them while they are JB Welded together.

Thanks to Darren for the Super 77’ing the skins together idea.

More Rear End Work

Posted in Skins on July 1st, 2008 by Samurai

The little panel on the rear skins wasn’t holding too well, I could push it out with my finger very easily. I decided to JB Weld it in from the back side.

I then went on to attach the large panel on the rear door. I again JB Welded this panel on to the door. After a while I checked to make sure the clamps did no adhere to the door.

Rear Door Work

Posted in Rear Door on June 30th, 2008 by Samurai

We had a picture party with the group we went to Israel with, so I didn’t have too much time to do much on R2. I took out 2 of the rear panels and mixed up some JB Weld. I applied the mess to the edges of the skins openings and clamped the panels in place. Next will be the large panel at the top and the 3 smaller ones at the bottom. The center door, I think I may make it a door as was shown in EPII.

Skin Attachment

Posted in Skins on June 29th, 2008 by Samurai

God has looked down on me and said that I can do some R2 work. We did have some storms come through, but it seemed that everytime I went outside teh sun came out. There wasn’t any hail or tornadoes. So…

Got to work on R2, for a little bit! For about 15 minutes on Friday I cut Out the inner rear skins octagonal port. Sunday I cut the front octagonal ports adn the power coupler. I then went to work on the rear skins. I detached the outer skins door panel. I then filed down any remaining burrs and tabs in the inner and outer skins. A quick clean up of the skins and they were ready to be attached.

I decided to go the Super 77 route. Sprayed the inner skin’s outside and the outer skin’s inside, make sense? 🙂 I attached the inner skin to the frame and started wrapping the out skin around. I used my cheap clamps the hold the skins in place as i went. I was going to take picture of the steps involved, but this stuff dries quick and needs to be put on while tacky. Just to be sure I kept the skins clamped for about 30 minutes. I took the clamps off and everything was solid.

i then moved onto the rear door. Again I clean the panels and sprayed each side and let dry. I positioned the panels and started attaching and clamping. After about 30 minutes and Took some the clamps off to see how it worked. The were some spots that did not stick, os I wiped up some JB Weld to seal the open seams. I didn’t think the Super 77 was going to hold well on the areas where there isn’t a lot of surface area. I will probably JB Weld the rear door’s panels on since that area will see some abuse being a door.

R2 build – Mother’s Day Weekend Edition

Posted in Skins on May 11th, 2008 by Samurai

With this being Mother’s Day Weekend, not much was done. On Friday I finished cleanup of the last of the panels on the rear skins. Each night I JB Welded 1 of the 3 panels.

This week the plans are to maybe cut the holes for the power couplers. Once these are done I can start putting the skins together. The main thing to get done this week though are the front panels, then I will be done with all the doors.

I hope to at least get the rest of the doors and maybe the rear door done this week. Next week maybe busy and build will stop again, until June, after that with our trip to Israel.

Back to work: More Skin Panels

Posted in Skins on May 9th, 2008 by Samurai

Just got into town after being on vacation. I started taking off more skin panels and prepping them for JB Welding. I need to go to the store and get some supplies, so I should be able to get them together tomorrow night.

Panel Doors Part 2

Posted in Skins on April 29th, 2008 by Samurai

I took the clamps off the panels and one of them didn’t weld together. I mixed up some more Jb Wled and resealed the panel.

I cut the center panel off the rear door and welded it together, just in case I do something with it in the future.

Panel Doors

Posted in Skins on April 27th, 2008 by Samurai

After the back door was cut I started removing panels. The first panels to be removed were the two large side doors in the back. I slipped my hacksaw into the slot and took out each tab holding the panel on. After the panel was detached I filed the tabs smooth. A quick clean up with acetone, the JB Weld was mixed up. The JB Weld was applied to the edge of the inner panel and then mated to the outer panel. Large black binder clips were used to hold the pieces together while the JB Weld hardened.

Coin Slots

Posted in Coin Slots, Frame on April 27th, 2008 by Samurai

First thing I had to do was check to see if the Coin slots fit the skins. A dry fit showed that they did not. I tested the openings to see which areas needed to be filed. After the openings were widened, I marked the location on the frame rings to be cut. A notch had to be made to allow the coin slot strip to sit in it’s proper place. After The marks were made, the dremel came out. A test fit and adjustment later, everything fit. I just have to mount the strip to the inner skins and they are done.

Rear Door

Posted in Rear Door, Skins on April 26th, 2008 by Samurai

i attached the inner rear skins to the frame and clamped the outer skins on. Using a pencil I marked the outline for the door. After the door was marked, I measured 1/8″ in and marked the cut line. Taking out the Dremel and a reinforced cutoff wheel, I slowly cut the inner skins. I just lined up the wheel on the line and let the wheel sink into the skins. I then moved the wheel up the line and repeated. This gave a pretty straight line. Every now and then I would stop and just make sure the line was not showing by lining up the outer skins. This was really just for my own sanity. A quick file down on the edges and the back door was cut off.