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and the finished part, primed and finally ready to be installed. Quite a bit of work for something as simple as a trunk strut mounting and latch system! I know, boring but it needed to be done!
and the finished part, primed and finally ready to be installed. Quite a bit of work for something as simple as a trunk strut mounting and latch system! I know, boring but it needed to be done!
2 2011/05/14 08:51:13
My brother and I toured the facility that built the bodies. Very cool place. Here are a few shots of the facility and one of the body molds. The insulated thing in back is their autoclave for the high dollar piece. this is the actual mold for the rear portion of the body.
My brother and I toured the facility that built the bodies. Very cool place. Here are a few shots of the facility and one of the body molds. The insulated thing in back is their autoclave for the high dollar piece. this is the actual mold for the rear portion of the body.
1 2011/05/11 19:05:13
The car arrived here in early March from my bro’s place where we cut off the fenders, made new ones and bonded them onto my car. This is what it looked like when it arrived. Rougher than i remembered during all of those weekends in CA! Now the real work began...
The car arrived here in early March from my bro’s place where we cut off the fenders, made new ones and bonded them onto my car. This is what it looked like when it arrived. Rougher than i remembered during all of those weekends in CA! Now the real work began...
0 2011/08/15 20:06:26
No matter what angle...she still looked might rough. The order of magnitude of the task was beginning to sink in!
No matter what angle...she still looked might rough. The order of magnitude of the task was beginning to sink in!
0 2011/08/15 20:06:12
Note that all of the black you see on each fender is raw carbon fiber cloth. Not really what most would consider suitable for paint! Also, since we glued the molded fenders on the existing body, the seams had to be completely integrated into the original body and the new shapes had to be contour matched as well. In other words….LOTS of bondo and more carbon fiber! So, I started smearing the bondo and broke out the sanding supplies.
Note that all of the black you see on each fender is raw carbon fiber cloth. Not really what most would consider suitable for paint! Also, since we glued the molded fenders on the existing body, the seams had to be completely integrated into the original body and the new shapes had to be contour matched as well. In other words….LOTS of bondo and more carbon fiber! So, I started smearing the bondo and broke out the sanding supplies.
0 2011/08/15 20:06:12
more bondo, more sanding.....
more bondo, more sanding.....
0 2011/08/15 20:06:12
still more bondo and still even more sanding....throw in a bit of shaping and contouring while you're at it!
still more bondo and still even more sanding....throw in a bit of shaping and contouring while you're at it!
0 2011/08/15 20:05:38
Finally, the left front fender starts to appear out of the bondo dust as I learn how to become a sculptor!!
Finally, the left front fender starts to appear out of the bondo dust as I learn how to become a sculptor!!
0 2011/08/15 20:05:38
Once the fender gets close…a dusting of guide coat is applied and then the fender lightly sanded…that shows you just how bad you did as the low spots magically appear all over the fender. Here is the same fender receiving the guide coat. After some light sanding, i realized i was still an "apprentice" sculptor.
Once the fender gets close…a dusting of guide coat is applied and then the fender lightly sanded…that shows you just how bad you did as the low spots magically appear all over the fender. Here is the same fender receiving the guide coat. After some light sanding, i realized i was still an "apprentice" sculptor.
0 2011/08/15 20:05:38
After lots and lots and lots and lots and lots and lots of sanding…more bondo and lots more sanding, it started to look like a Lister…a REALLY wide Lister that is (it is about 4 inches wider than a late model Corvette Z06!!).
After lots and lots and lots and lots and lots and lots of sanding…more bondo and lots more sanding, it started to look like a Lister…a REALLY wide Lister that is (it is about 4 inches wider than a late model Corvette Z06!!).
0 2011/08/15 20:05:13
Then the body started to appear from the clouds of bondo dust…I am a terrible body dude and sand off 90% of all the bondo I apply…so, I apply a lot of bondo! But...it was actually starting to look good - to my utter surprise.
Then the body started to appear from the clouds of bondo dust…I am a terrible body dude and sand off 90% of all the bondo I apply…so, I apply a lot of bondo! But...it was actually starting to look good - to my utter surprise.
0 2011/08/15 20:05:13
As the fenders come into the right shape… I then add glazing putty to fill scratches and low spots (the reddish brown stuff). While the fenders are getting smoother and better shaped, the putty makes them look even worse…if that is possible. Ok, so it still looks pretty rough…believe it or not…it is getting better. I pretty much worked on it every weekend with a goal of getting it ready for paint by the end of the summer (a goal i did not attain). Well, that is about it for this update.
As the fenders come into the right shape… I then add glazing putty to fill scratches and low spots (the reddish brown stuff). While the fenders are getting smoother and better shaped, the putty makes them look even worse…if that is possible. Ok, so it still looks pretty rough…believe it or not…it is getting better. I pretty much worked on it every weekend with a goal of getting it ready for paint by the end of the summer (a goal i did not attain). Well, that is about it for this update.
0 2011/08/15 20:05:13
Our goal over the past several weekends was to finish the rough shape of the fenders and then cover the body with one final layer of carbon fiber to give it strength. First step was to work on and develop the front fender shape and integrate the large flare into the overall shape of the car. We wanted a wide look without disruption the classic profile of the Lister/Jag style.
Our goal over the past several weekends was to finish the rough shape of the fenders and then cover the body with one final layer of carbon fiber to give it strength. First step was to work on and develop the front fender shape and integrate the large flare into the overall shape of the car. We wanted a wide look without disruption the classic profile of the Lister/Jag style.
0 2011/08/15 19:25:47
Once happy with the shape (after LOTS of sanding and bodywork), we then trimmed a nice single piece of carbon fiber cloth to fit the new fender.
Once happy with the shape (after LOTS of sanding and bodywork), we then trimmed a nice single piece of carbon fiber cloth to fit the new fender.
0 2011/08/15 19:25:47
with a good fit using the cloth, we applied the vinylester resin to permanently laminate the carbon skin to the body. Now it was finally staring to look like all of our work would pay off!
with a good fit using the cloth, we applied the vinylester resin to permanently laminate the carbon skin to the body. Now it was finally staring to look like all of our work would pay off!
0 2011/08/15 19:25:47
We followed the same procedure on the other side as well and had a nice, aggressive look from up front. Now, if you remember, the new rear quarter panels did not fit well and there was a 1 inch gap at the rear of the new flare. So…we “bagged” the fender in preparation for the “pour foam” treatment. We then filled the bag with the liquid foam and allowed it to cure and expand with a little help from our heat source (it was pretty chilly in No Ca when we were doing this).
We followed the same procedure on the other side as well and had a nice, aggressive look from up front. Now, if you remember, the new rear quarter panels did not fit well and there was a 1 inch gap at the rear of the new flare. So…we “bagged” the fender in preparation for the “pour foam” treatment. We then filled the bag with the liquid foam and allowed it to cure and expand with a little help from our heat source (it was pretty chilly in No Ca when we were doing this).
0 2011/08/15 19:24:44
Then we removed the bag and started shaping with a crosscut saw (now we’re on the passenger side) the pour foam shaped nicely and gave us a smooth contour despite the lousy fitment of the rear quarter panels. Here is the quarter panel part way through the shaping process. I know, it looks horrible and rough but...it's the finished product that counts, right?
Then we removed the bag and started shaping with a crosscut saw (now we’re on the passenger side) the pour foam shaped nicely and gave us a smooth contour despite the lousy fitment of the rear quarter panels. Here is the quarter panel part way through the shaping process. I know, it looks horrible and rough but...it's the finished product that counts, right?
0 2011/08/15 19:24:44
With a bit more shaping and sanding, the rear quarter was starting to look good...yes? well, maybe not, but after several very long chilly days, we decided it looked better!
With a bit more shaping and sanding, the rear quarter was starting to look good...yes? well, maybe not, but after several very long chilly days, we decided it looked better!
0 2011/08/15 19:24:44
Still too rough for the carbon fiber skin…the dreaded bondo was applied generously to aid in the final contouring of the quarter panel…followed by a LOT of sanding and mess making. Clearly, all this sanding makes your hair begin to fall out...at least that is my theory and I'm stickin' to it!
Still too rough for the carbon fiber skin…the dreaded bondo was applied generously to aid in the final contouring of the quarter panel…followed by a LOT of sanding and mess making. Clearly, all this sanding makes your hair begin to fall out...at least that is my theory and I'm stickin' to it!
0 2011/08/15 19:23:19
Just like the front, we finally were able to laminate the carbon skin over each of the rear quarterpanels. It felt good to be making progress but, honestly, the car still looked pretty rough.
Just like the front, we finally were able to laminate the carbon skin over each of the rear quarterpanels. It felt good to be making progress but, honestly, the car still looked pretty rough.
0 2011/08/15 19:23:19
A bit of trimming to clean up the fender arches and we now have completed the four corners! Here is a shot when we wrapped up the project for that weekend – its kinda, sorta starting to look like something you might want to drive…almost anyway. Of course, with all of the back slapping and congratulations we gave each other at this stage, we kind of overlooked the massive effort required to turn this into what the car looks like today. It was a fun time but, i am really glad to be done with that part of the project.
A bit of trimming to clean up the fender arches and we now have completed the four corners! Here is a shot when we wrapped up the project for that weekend – its kinda, sorta starting to look like something you might want to drive…almost anyway. Of course, with all of the back slapping and congratulations we gave each other at this stage, we kind of overlooked the massive effort required to turn this into what the car looks like today. It was a fun time but, i am really glad to be done with that part of the project.
0 2011/08/15 19:23:19
1 After getting the body bonded on the chassis and getting the chassis mobile, my bro towed my car up to his place in Oakland CA to work on the body since it is much warmer than here in VA. We made the flares with about 20 lbs of bondo applied to the body and then make molds for new front and rear fenders. Here is the passenger side mold for the front fender flare area:
1 After getting the body bonded on the chassis and getting the chassis mobile, my bro towed my car up to his place in Oakland CA to work on the body since it is much warmer than here in VA. We made the flares with about 20 lbs of bondo applied to the body and then make molds for new front and rear fenders. Here is the passenger side mold for the front fender flare area:
0 2011/07/08 17:55:27
2 This is the process of laying up the widened front fenders. Both and done and curing in the No. CA sunshine (a good thing it was sunny because the hills of Oakland do not get very warm in January!).
2 This is the process of laying up the widened front fenders. Both and done and curing in the No. CA sunshine (a good thing it was sunny because the hills of Oakland do not get very warm in January!).
0 2011/07/08 17:55:27
3 Using the same process, we made molds for the very wide rear quarter panels and then laid up the panels. Here is the "raw" passenger side rear quarter panel in the rough.
3 Using the same process, we made molds for the very wide rear quarter panels and then laid up the panels. Here is the "raw" passenger side rear quarter panel in the rough.
0 2011/07/08 17:55:27
4 Next, we removed all of the bondo and started laying out the cut lines required to maximize tire clearance for the much wider wheels and tires.
4 Next, we removed all of the bondo and started laying out the cut lines required to maximize tire clearance for the much wider wheels and tires.
0 2011/07/08 17:55:05
5 The sawsall made making tire clearance a piece of cake - just didn't really look all that great...
5 The sawsall made making tire clearance a piece of cake - just didn't really look all that great...
0 2011/07/08 17:55:05
6 Next, i took the sawsall to the rear and, in just a few minutes, had massive tire clearance back there as well.
6 Next, i took the sawsall to the rear and, in just a few minutes, had massive tire clearance back there as well.
0 2011/07/08 17:55:05
7 Now the really fun part…fitting the new panels. The fronts fit fine because we made the molds off of my front fenders. There they are after trimming and while we are fitting them to the car. Also, you can see the poorly fitting rear quarter panels – they were made from molds from my bros car which, we now know, is VERY different than my car (yes we are building one for him as well):
7 Now the really fun part…fitting the new panels. The fronts fit fine because we made the molds off of my front fenders. There they are after trimming and while we are fitting them to the car. Also, you can see the poorly fitting rear quarter panels – they were made from molds from my bros car which, we now know, is VERY different than my car (yes we are building one for him as well):
0 2011/07/08 17:54:44
8 The fitment of the rear quarters was simply "outstanding" - not. these required a lot of work to make them fit.
8 The fitment of the rear quarters was simply "outstanding" - not. these required a lot of work to make them fit.
0 2011/07/08 17:54:44
9 Here, little Bro helps with the trimming and shaping of the wheel arch on the driver side rear quarter panel. we both itched for weeks after this project!
9 Here, little Bro helps with the trimming and shaping of the wheel arch on the driver side rear quarter panel. we both itched for weeks after this project!
0 2011/07/08 17:54:44
10 Now the front fenders are epoxied and screwed onto the body. the extra wide shape is starting to become evident and the car is already looking much more agressive.
10 Now the front fenders are epoxied and screwed onto the body. the extra wide shape is starting to become evident and the car is already looking much more agressive.
0 2011/07/08 17:54:20
11 Same process on the rear but the rear just would not cooperate and the fitment was pretty poor. We addressed this later with lots of pour foam and shaping - but that is for another story!
11 Same process on the rear but the rear just would not cooperate and the fitment was pretty poor. We addressed this later with lots of pour foam and shaping - but that is for another story!
0 2011/07/08 17:54:20
12 Now we could admire the very wide backside of the Lister. It is 77 inches wide from fender lip to fender lip!
12 Now we could admire the very wide backside of the Lister. It is 77 inches wide from fender lip to fender lip!
0 2011/07/08 17:54:20
13 The front, while quite a bit narrower than the rear is still substantially widened over the "stock" body. we added just under 7 inches to the width up front!
13 The front, while quite a bit narrower than the rear is still substantially widened over the "stock" body. we added just under 7 inches to the width up front!
0 2011/07/08 17:53:42
14 We also had to reinforce the fenders from the underside with fiberglass tape. What a pleasure it is to lay up fiberglass and resin upside down. We only got the drivers side front fender done during this very long 4 day weekend (12 to 14 hours per day)
14 We also had to reinforce the fenders from the underside with fiberglass tape. What a pleasure it is to lay up fiberglass and resin upside down. We only got the drivers side front fender done during this very long 4 day weekend (12 to 14 hours per day)
0 2011/07/08 17:53:42
15 So, this is what we accomplished in just 4 days. we even started the process of shaping the front fenders and blending them into the body. Unfortunately, i had to pack my bags, put the car away in his garage and fly back east to get back to the office. the next trip would prove to be both quite interesting and very challenging.
15 So, this is what we accomplished in just 4 days. we even started the process of shaping the front fenders and blending them into the body. Unfortunately, i had to pack my bags, put the car away in his garage and fly back east to get back to the office. the next trip would prove to be both quite interesting and very challenging.
0 2011/07/08 17:53:42
5 1 Making progress - I actually put the wiring harness in the chassis fairly early on to make it easier to pull all of the wires. In this picture you see a steel non-collapsible steering column. I was not too thrilled at the prospect of being skewered by my own steering column so i replaced it with a NASCA collapsible column. Of course, it didn't fit and that resulted in a whole new project...see later in this album.
5 1 Making progress - I actually put the wiring harness in the chassis fairly early on to make it easier to pull all of the wires. In this picture you see a steel non-collapsible steering column. I was not too thrilled at the prospect of being skewered by my own steering column so i replaced it with a NASCA collapsible column. Of course, it didn't fit and that resulted in a whole new project...see later in this album.
0 2011/06/18 07:38:11
5 2 Here i have fitted the trunk, trunk hinges, and the latch. Boy was it difficult to get the carbon fiber panels to line up with any precision at all.
5 2 Here i have fitted the trunk, trunk hinges, and the latch. Boy was it difficult to get the carbon fiber panels to line up with any precision at all.
0 2011/06/18 07:38:11
5 3 The pedals are installed for the first time. a bit tight and difficult to work in but, they fit. adjusting them is a pleasure (not). to provide better access, i cut the top of the foot well off and made an access panel so you could get to the pedals from above (see the next photo)
5 3 The pedals are installed for the first time. a bit tight and difficult to work in but, they fit. adjusting them is a pleasure (not). to provide better access, i cut the top of the foot well off and made an access panel so you could get to the pedals from above (see the next photo)
0 2011/06/18 07:38:11
5 4 Here are the master cylinders from the top. The cylinder at the bottom of the photo is the clutch, the center one actuates the rear brakes and the top is for the front brakes. I must have put these pedals in and out of the chassis at least a dozen times over the past 4 years!
5 4 Here are the master cylinders from the top. The cylinder at the bottom of the photo is the clutch, the center one actuates the rear brakes and the top is for the front brakes. I must have put these pedals in and out of the chassis at least a dozen times over the past 4 years!
0 2011/06/18 07:32:06