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johnnyp
06-06-20, 06:06 PM
Hi all,

Now that I have cleared out the garage, found my way to my Dax and cleared most of the dust from it, I thought I would start a build diary.

Given that I started building my Dax in 2010, I don't plan to go right back to the start but will carry on from where I left off all those years ago!!

First off a job I had been putting off for a looong time, re-profiling the inner shape of the door to better match my proposed flat dashboard.

Step one cut out the fibreglass not required:
https://flic.kr/p/2j9huD3

Next step fill the void with some aluminium mesh:
https://flic.kr/p/2j9huaY

Then laid 4 layers of GRP cloth and resin:
https://flic.kr/p/2j9mrXs

Then fill to shape...I hate filling took me ages:
https://flic.kr/p/2j9mrka

But eventually looked ok:
https://flic.kr/p/2j9kcjR
https://flic.kr/p/2j9hyDH

Need to get on with the dash now!

johnnyp
06-06-20, 06:07 PM
Oh yes and how do you upload images?

johnnyp
06-06-20, 06:28 PM
https://live.staticflickr.com/65535/49976844958_40b2bf20b3_c.jpg (https://flic.kr/p/2j9hoQE)IMG_2530 (https://flic.kr/p/2j9hoQE) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr
https://live.staticflickr.com/65535/49976864468_f141c88f9a_c.jpg (https://flic.kr/p/2j9huD3)IMG_2535 (https://flic.kr/p/2j9huD3) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49976862898_4f37fda6c8_c.jpg (https://flic.kr/p/2j9huaY)IMG_2538 (https://flic.kr/p/2j9huaY) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49977635892_501411b8f6_c.jpg (https://flic.kr/p/2j9mrXs)IMG_2543 (https://flic.kr/p/2j9mrXs) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr[/img]

https://live.staticflickr.com/65535/49977633787_777f167835_c.jpg (https://flic.kr/p/2j9mrka)IMG_2550 (https://flic.kr/p/2j9mrka) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49977391561_ea05582714_c.jpg (https://flic.kr/p/2j9kcjR)IMG_2551 (https://flic.kr/p/2j9kcjR) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49976877963_7438064c93_c.jpg (https://flic.kr/p/2j9hyDH)IMG_2552 (https://flic.kr/p/2j9hyDH) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

jon1d
06-06-20, 06:28 PM
1.Go to "Go Advanced" bottom right of when your create a post.

2. Open "Manage Attachments"

3. Click "Add file"

4. Click "Choose File " Locate your photo you wish to upload.

5. Click "Upload"

Repeat step 3 -5 for each photo.

6. Once you have added all the photo's hit done.

7. If you wish to delete the photo before you submit your post. Click on the photo ICON , click on the "X" in the top right corner deletes the photo is loaded in error.

There are restrictions on the size of the photo file and the photo ratio. If it does not upload then resize the photo to a <2 meg

KevinW
08-06-20, 09:35 AM
Nice work-- -well done!

johnnyp
09-06-20, 09:46 PM
So a long time ago I got fed up with the crappy Dax gas struts on the boot, next step was to trial one of those ratchet type struts, nope didn't get on with that either, plus it made the boot lid sit wonky when it was propped open.

Solution, home made prop, a little over engineered and it cuts across the boot opening a bit but I like it, also made a little cover for the latch, think I'm going to do the same for the bonnet!

https://live.staticflickr.com/65535/49989472537_3133ebb8b7_c.jpg (https://flic.kr/p/2jap7zx)IMG_2571 (https://flic.kr/p/2jap7zx) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49989228016_ec738b2205_c.jpg (https://flic.kr/p/2janRTE)IMG_2572 (https://flic.kr/p/2janRTE) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49988705868_7c4db197bb_c.jpg (https://flic.kr/p/2jakbF7)IMG_2573 (https://flic.kr/p/2jakbF7) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

https://live.staticflickr.com/65535/49989229776_6ca402da0d_c.jpg (https://flic.kr/p/2janSq1)IMG_2577 (https://flic.kr/p/2janSq1) by John Prentice (https://www.flickr.com/photos/188697144@N08/), on Flickr

aaronjb
10-06-20, 09:03 AM
Damn, John .. your aluminium boot panels put mine to shame! Great shame! The fit and finish is absolutely spot-on, and you're making me feel like starting mine over :) Care to share any tips & secrets for getting such a neat finish? Like .. how did you get your rivet heads so flush (just grind them back?), your bends and joins so neat, and your edges so perfect.. and those doors have such a beautiful fit! *cries into his tea* Also please tell me that sheet metal work has been your day job for the last 40 years, so I feel less bad :mrgreen:

You also remind me that I need to finish the plinths where my internal boot hinges attach - and re-bond the hinge loop to the rear deck on one side, Würthless Würth..

KevinW
10-06-20, 09:33 AM
Steady Aaron - John's work looks fabulous - but your boot is perfectly good, and certainly better than mine.
Just a little note to your future self: don't let your 10 year anniversary pass without having got an IVA test out the way!
You can always prettify it after.

Bigblock
10-06-20, 09:54 AM
That's boot work looks supurbbbb.

Arron, stop reading and looking at things.
Just concentrate on what you have already ;-)

Liking the mod to the doors as well, something I have always thought about, but too many jobs on the go to be cutting the car about at the moment.

jon1d
10-06-20, 11:36 AM
Neat aluminium boot work. Love the finish and are those rivets counter sunk ? What ali thickness you using and type of ali. I agree with the gas struts on the back they limit the boot opening and I have had to remount them a couple of times also loosing there air.

johnnyp
10-06-20, 01:16 PM
Hi all, thank you for the positive comments, very much appreciated, however the flaws and gaps are there but the photos do a good job of hiding them!

Nothing wrong with your panelling Aaron, I'm sure once its complete it will look the nuts!

regarding the comments....

Aluminium is mostly 2.0mm and 1.5mm.

Tips and tricks, hmmmm, the rivets are countersink so it is important to use the correct countersinking tool, if the rivets are 120 degree or 90 degree head then countersinking with the end of a drill won't give good results, so best bet is picking a good quality countersinking tool, I also check the depth of each countersink hole with a rivet as I go, countersinking a bit deeper if I need to.

As for bending, I have a good small 'bending machine' that gives nice bends, again if you are going to be doing a lot of fab work then a small press is worth its weight.

Other than that its a case of nice sharp tools and lots of filing to get the edges straight, I also try to place the edge of one panel against a flat panel (i.e. not edge to edge) where I can as this hides wonky lines quite well.

Oh yes and Scotch Brite pads are excellent for giving a brushed appearance.

I would however echo Kevin's comment, that panel work probably took me 6 to 8 months if not longer (and de-motivated me a number of times), looking back I would rather have cracked on and finished the car and enjoyed it rather than prettifying it.

Never mind nothing else to panel in aluminium now so it must be a clean run to the finish lol!!