How to build in just 12 years: My Glitter..er.. KC Clipper

[Big_kid]

Third time's the charm...

Letting it dry a day or two, then going over to CN's place to scuff it up one night this week after work. A little more clear, then it's off to the races. I'm not thinking I'll make it to MOTB this year, but whatever. That's not what I'm building it for.

[Raj]

LOOKING GOOD CHARLIE!

[Big_kid]

Thanks, but this is ALL Matt's doing. I picked the colors, I sand, and until last weekend I taped. I'm NOT a body guy by any stretch of the word. BTW- 2 tone flake paint.... crap ton of work. I honestly didn't know what was involved in something like this, otherwise I'd have gone with straight up paint.

Getting antsy again...

[Big_kid]

The hood got some scuffing and some clear, the plan is to scuff it again and give it one more go around hopefully this weekend. Then it's time to do the same to the body.

Video of shiny object:
http://vid249.photobucket.com/albums/gg ... nzibne.mp4

[Raj]

PUUUUURDY!

[Big_kid]

No real progress since last post, but I did pick up a bedliner kit for the pan. Spray paint just doesn't hold up on the floor, i didn't really expect it would. I also got to looking at the tunnel and decided I really should patch the holes someone cut into it while access is easy and before I rhino liner it.

If I remember correctly the way to do it is to cut a piece of cardboard to fit, transfer it to 18 - 20 gauge sheet metal, trim to fit the hole, hold it with a magnet, tack it in, then butt weld it up? Am I under thinking this, over thinking this, or just shut up and do it already?

I'll get some pics here in a few, they're pretty big holes.

[Big_kid]

url=http://s249.photobucket.com/user/buggy_ ... h.jpg.html][/url]

[Raj]

If I remember correctly the way to do it is to cut a piece of cardboard to fit, transfer it to 18 - 20 gauge sheet metal, trim to fit the hole, hold it with a magnet, tack it in, then butt weld it up? Am I under thinking this, over thinking this, or just shut up and do it already?

Depending on how visible the holes will be once repaired, shoudl drive the time spent on getting the patch perfect. Def not structural, and if it will be covered by the carpet ( IF you have carpet) you may eve want something removal for access in the furture; depending on the hold location. if its in plain sight I make a nice patch and no would ever be the wiser once its ground down and painted.

[Big_kid]

I was sitting in traffic thinking about it today, and thought about making the patches larger than the holes and just covering it that way.

Raj, you don't think this is structural? It's in an open buggy, no more metal body. There's a hole to access the pedals on the passenger side and another on the driver side behind the E brake, presumably for clutch tube access. Putting all this into it, I just want to get it right and stay safe.

[Raj]

I was sitting in traffic thinking about it today, and thought about making the patches larger than the holes and just covering it that way.

Raj, you don't think this is structural? It's in an open buggy, no more metal body. There's a hole to access the pedals on the passenger side and another on the driver side behind the E brake, presumably for clutch tube access. Putting all this into it, I just want to get it right and stay safe.

Your basically sitting in kiddie pool traveling on the road 60 MPH..... so you are worried about occupant safety or vehicle rigidity? I actually sold my buggy mainly due to some safety concerns ( most externally.... ie other drivers)

If you have concerns, weld the patch bigger then the hole with spot welds, so You can grind the welds off easy if you need access. Chances are you will never need access. So if you have any material concerns about it.... weld them shut with the intention you wont need the access. If you need it, get the hole saw.

[Big_kid]

I was thinking rigidity, being that it's the spine of the car. I'll find some 18-20 gauge and weld over it. Bedliner will help hide it, not that they'll be that noticeable. Gotta get busy on it now.

[Big_kid]

I spent some time yesterday with the welder, good thing I did- I never put 2+2 together. Someone cut an access panel in the bottom of the tunnel in the same spot where the front hole was, directly across from the pedals on the passenger side. There was no structure underneath and this hole... scary. There were cracks about an inch long each at 11, 1, and 7 o'clock positions. I drilled a stop hole on each, welded them up, and welded a patch over that. I got a patch cut for the hole at the back end of the tunnel, but a thunderstorm rolled in, I had to close up shop. I've got a thread on my FB wall, I'll get them into photobucket and onto here when I can. I WILL be driving this buggy again this summer.

[Big_kid]

For posterity's sake...
That bracket inside looked like it should have been secured, so it was welded first:





I never claimed to be good at it...


Tack the patch on, shape it to the tunnel



Make a relief cut so it sits better


Warm up the dryer circuit breaker a bit more



Yep. Sums it up.



as it sits, waiting for me to patch the other hole, then lay on the Herculiner


P O wasn't hesitant about cutting into the tunnel...


This is where I had to stop


Thunderstorm rolled in, several lightning strikes in the neighborhood. Photobucket isn't showing the pic for whatever reason.

[Raj]

Great job Charlie. Its getting closer my friend!

[Big_kid]

Thanks! It is getting closer, I want to be driving this thing next month. I'm off the week of July 4th, I'm hoping Matt and I can get the clear coat finished soon so I can get cracking on reassembly.

[Big_kid]

I got that last patch on the tunnel Sunday after we got home from camping. My welds looked like a stack of dimes... had been stolen and used to buy a pack of bubble gum. I figured there wasn't going to be a day with longer daylight than today, so I broke out the Herculiner. Didn't get any on me until cleanup, it wasn't exactly pleasant washing my face with Xylol. I was expecting worse.

Driver side by the e-brake:


Brushed on the liner...






After the second coat(I think?)

[Raj]

Looking good! Almost time to mount the body back on?

[Big_kid]

Yes. The body needs two or three more coats of clear, the hood needs one. Then it's build time. Again.

[Big_kid]

Today I helped Matt with the last of the clear coat. I took some pics but honestly, in pics, it looks the same as the last batch. Only difference is the shiny clearcoat in those pics was scuffed up and sprayed over today. The good news though: The clear is finished. It needs to harden for a few days, then the body comes home for assembly. A lot has happened at both Matt's house and ours the past 2 years, but it's coming together, finally. I really hope to be driving it in a few weeks. I don't have to reinvent the wheel this time, I just have to be careful reassembling it. There is no more krylon touch up.

Soon... (I hope!)

[Raj]

almost there good buddy....!

[Big_kid]

No pics on the computer yet, but the body is mounted. I used garage door gasket between it and the pan, more around the perimeter of the gas tank, and have enough left to go under the windshield. That stuff seems to fit everywhere.

Earlier today I was out playing in the heat, I got the fuel filler door and the gas tank mounted. I had to stop as I had volunteered to sling beer and fries at the Dixie Chicks concert tonight.

Pics as I get them uploaded...

[Big_kid]

Waited until the last minute to cancel campground reservations, decided to work on the buggy this weekend instead. Had a delay yesterday, had to paint the front of the house to keep the city happy (it had been power washed and was on the radar screen, just wasn't originally yesterday's blip).

Today saw the 2 fuse boxes mounted (hot and switched), hot wire ran to the battery box, sticky tabs under the passenger side lip where I forgot to glass in chunks of pool hose to hold the wires on that side, tail lights mounted, tag light mounted.

[Big_kid]

The hood isn't mounted yet...

[elrockk]

lookin good Getrdone

[Big_kid]

Thanks! Looks like we're both getting close!