Here's the latest progress on my build. It's been very very slow as my wife fell ill again, and was bedridden for about a month. As time permitted, I did get some small things done.
I did come to terms with my tubing bender and developed a practical method of working single handed with the aid of a propane torch, a wooden lever and an old drafting chair as a second set of hands.
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I was developing a technique of bending and rolling the upper boot hoop to match the Caterham lines. The plan was to make it in two pieces, joining them on the centerline using some 3/4" DOM tubing turned down on the mini-lathe to fit inside the ends & welding all 3 parts together. A one piece hoop would be too awkward for me to do on my own, both bending and rolling at the same time.
I started doing some practice pieces in cheap conduit to work out the details. While playing with the angle of the conduit , it struck me - the straight conduit worked just fine to impart the dynamic feeling I wanted at the rear. A straight hoop with just two 90° bends would also make my life a lot simpler. Duh! Why didn't' I think of that the first time?
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So, I built some temporary locators to hold the upper hoop in place while I fitted the hoop and the verticals needed for the spare tire carrier and the rear roll bar braces.
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Next, I fab'ed and located the verticals, and put my cardboard template for the cockpit piece (black line locates the fender shape) in place to make sure it worked with the hoop angle. I'm actually quite pleased with the setup.
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Now that I'm happy, I'll full weld everything and get on to designing and building the spare tire carrier, which will also have the license plate brackets, and maybe the backup lights too.
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Cheers,