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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 20, 2015, 8:09 am 
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Jerminator96 wrote:
The reason I ask is that the solid bar mine came with is bent now. Of course, I use my bender for 1.75"x.125" DOM, so it's bound to be under a little more strain.


You need hardened steel pins for sure. I've read stories of people breaking the aluminum dies trying to bend oversized 4130 stock. I expect the heaviest I'll do is 1 1/2 x .125

I read a good bit on line before I decided to buy this type die. The Pro Tools die set is nicer and bends up to 180° using the Got Trikes type bender.
There were a couple of things I didn't like about building that particular rig. First, I'd have to gain access to a machine shop to put all the multitude of holes in the parts. Second, I'd need a jack with a REALLY long stroke. Third, I didn't have all the steel just lying about the garage.

Today I'll get some steel bar from the scrapper and hopefully make bushings to keep the die centered in the rig.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 20, 2015, 9:40 am 
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I decided to sell one of my earlier projects on Craigslist over the weekend. This is a bunk bed I built for my son when he was about 3 or 4. It's set up in Baby Girl's room right now since he outgrew it.

Side rails are 2x6. Posts are laminated 1x4's and the construction is mortise and tenon. End rails are 2x4 with wooden dowels The ends attach to the side rails with heavy duty lag bolts.

I laminated the posts because I didn't have a good way to cut an accurate mortise. I notched the middle ply of the laminate on my table saw so that it would be a light press fit when I cut the tenons on the 2x4's.

Kids grow, times change, turn the page.

Attachment:
bunk bed.jpg
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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 23, 2015, 7:17 pm 
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30 minutes in the garage after work today
My latest Craigslist purchase showed up yesterday, a really old heavy duty shrinker stretcher set. Not deep jaw style, but hey, they were cheap enough

First up, cut a strip and bend 90 degrees
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Then a pass thought the stretcher to get the flatter radius for the back edge of the car
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lip3.jpg
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Then stretch the sharper curve of the corner.
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lip2.jpg
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And make it's mate for the left side
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lip1.jpg
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Then the center bit with the shallow radius

Not bad for 30 minutes work
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lip.jpg
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But 30 minutes is enough time to get a blister from crankin on the stretcher handle
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hand.jpg
hand.jpg [ 615.5 KiB | Viewed 3036 times ]

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

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http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 23, 2015, 7:24 pm 
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A great 30 minutes worth of work! And I see in the photos you were wearing gloves. Must have taken a lot of effort to pop up that blister.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 23, 2015, 7:28 pm 
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stretching 17 gauge steel is a workout. I see why people buy foot pedal bases for them.

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

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http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 23, 2015, 7:38 pm 
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Dang that looks awesome. How difficult is it to gauge how much it shrinks or stretches or is it just little by little until it fits?

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 23, 2015, 7:59 pm 
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It stretches a bit less than 1/16 inch per stroke. You have to get a feel for how much curve it generates and space out the distance between stretches. The cool thing I learned watching a Ron Covell video on youtube is you can always stretch it more and you can always shrink it if you go too far.

The first one I test fit it about 5 times. The second one took 2 test fits and the rear shallow arch I got luck and popped it out on the first go.

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 25, 2015, 6:19 pm 
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Fun day at the Too Busy house today.
First up, rolled out of bed at O-Dark Thirty to jump in the Miata and go pick up the donor for the F600 project. Had a cup of coffee and hit the road for a 116 mile ride to the other side of Columbia, SC.
I got up there and the bike was well described by the pictures. Talked with the family and heard the story... sad, really sad

Loaded the trailer and set sail for home. 11am pulled in the driveway.
Attachment:
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It was raining pretty hard, so time to get to work on the Mini. There was no putting it off any longer. I had to cut away the rusty rear flange and the bottom rear corners of the car. I should have taken more pics :oops:

I took my time with the cutoff wheel and got a pretty decent line at the bottom of the trunk opening. Once that was set I had to final trim the bent center piece I made the other day.

Clamp in place. tack, hammer to even up, tack, clamp another spot , tack, repeat, repeat, repeat,...
Once all the tacks were in place, stitch weld the flange

After welding, rough grind. I need to work on the corners tomorrow and hammer / dolly and metal finish

Attachment:
rsz_rear_lip.jpg
rsz_rear_lip.jpg [ 1.07 MiB | Viewed 2974 times ]

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 26, 2015, 5:35 pm 
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More cutting, grinding, hammering and welding on the Mini today.

FIRST, let me say that I AM NOT a metal smith and I don't even play one on TV. I am willing to try anything at least once though.

When we left off yesterday I had roughed in the center section of a new rear flange and had cut away the rusty bottom corners at the back of the car. Today's mission was to make and rough in the missing pieces.

Clamp on the bottom flange piece so I can mark the profile of the rear valance lip.
Attachment:
rrf1.jpg
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Then mark and make a metal template for the little patch for the side panel.
Attachment:
rrf2.jpg
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Then make the real patch piece and wheel a little compound curve into it
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rrf3.jpg
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Attachment:
rrf4.jpg
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Hammer and stretch the lips on it and weld in place. I welded the lip onto the flange piece and offered it up to check the fit.
Attachment:
rrf5.jpg
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Then made the missing piece
Attachment:
rrf6.jpg
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Attachment:
rrf7.jpg
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Still needs finish welding and metal finishing but it's all solid.

Did the same to the other side too
Attachment:
lrf.jpg
lrf.jpg [ 594.6 KiB | Viewed 2936 times ]


Butt load of work in remaking this part of the car. My little MIG gun doesn't like running on the lowest setting, but no choice. Higher heat just blows up the old metal.

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 27, 2015, 10:47 am 
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Back in the office today and just spent the past 1 1/2 hours on a conference call.... great time to do some internet shopping.

As the rust repair is SLOWLY getting near the end I'm thinking about paint and interior. This will be a cute little Clemson car, so Orange with a White roof and White stripes. What I haven't decided is painted stripes or vinyl.

Here's the question to the group - Would the inside look better Orange with black seats and trim carpet or White with black seats and trim?

I'm leaning toward White but it adds another level of complexity to the painting, which we all know isn't really my strong suit.

And I think it needs a BIG OLE Paw on the roof.
Attachment:
tiger paw.jpg
tiger paw.jpg [ 35.39 KiB | Viewed 2889 times ]

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OOPS I did it again
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http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 27, 2015, 9:49 pm 
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And I think it needs a BIG OLE Paw on the roof.
Make that a RED Wolfpack Paw, and you'll have something. That funny Urnge :puke: color just makes it a better target. :mrgreen:

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Last edited by GonzoRacer on April 27, 2015, 10:49 pm, edited 1 time in total.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 27, 2015, 10:11 pm 
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GonzoRacer wrote:
Quote:
And I think it needs a BIG OLE Paw on the roof.
Make that a RED Wolfpack Paw, and you'll have something. That funny Urnge :puke: color ust makes it a better target. :mrgreen:


Now you're talking. :cheers:


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 27, 2015, 11:36 pm 
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I vote for a white interior with black upholstery. The orange and black would be too halloweenie (is that a word?) for my tastes.

And, at the risk of offending you, I don't like the paw on the roof because the paw has nothing to do with classic minis.

That's my $0.05 worth (has to be a nickel since we eliminated pennies in Canada). Looking forward to seeing the results though no matter what you pick.

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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 28, 2015, 7:58 am 
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Quote:
Make that a RED Wolfpack Paw, and you'll have something. That funny Urnge :puke: color just makes it a better target. :mrgreen:


Sorry JD and Jerms, no Pack fans in this house. With both my Cubs up the hill I've gotta be Solid Orange


Quote:
vote for a white interior with black upholstery. The orange and black would be too halloweenie (is that a word?) for my tastes.

And, at the risk of offending you, I don't like the paw on the roof because the paw has nothing to do with classic minis.


Your thinking and mine are right in line on the Halloween theme. I'm getting ever closer to finishing welding, so I have to make a decision in the next couple of weeks.

The paw print will be a vinyl graphic. This will be an awesome little tailgating car and the Tiger Paw will fit right in. Down the road it's easy enough to remove.

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OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Too Busy's Mk I Mini
PostPosted: April 28, 2015, 8:28 am 
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I think you need to be as bright as possible for visibility. I like orange white top and the paw print.


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