one way to make a rad shell

[godspeed]

Some guys asked me how I was making the rad. shell on the speedster.. So here's a little tech using LOW BUCK tools (ex. the welder ).

First thing I did was to make a pattern. I did two different ways; one paper and one using a fexiable shape pattern.
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The flex pattern is just several layers of tape, first layer is painters tape folowed by two more layers of fiberglass tape.

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Here the patterns are on the buck
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Then I cut out the blanks with about a 1/2in extra all the way around (for trimming and welding)
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NOW I told you that I was doing this LOW BUCK... It doesn't get any cheaper than this... Baseball bat mallet and a hollowed out stump

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You start hitting the metal down into the hollow as a fold forms you smack it down flat
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this is what you get after about ten minutes work,, a roughed out shape
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Now you have to 'planish' smooth. I used a dolly and slapper made out of a old leaf spring.. Just hitting it lightly until the lumps disappear
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[godspeed]

Here's the two pieces ready for a little trimming
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Now I placed them on the orginal rad shell and scibed them for a final trim and welded them together.
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And with a little filing and sanding you get this
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And you can still see the hammer marks on the inside
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Here's some of the finishing steps...
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Cut out square blanks, bend into a radius, trim to fit ,weld.....
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Got all trimmed up and got ready for the step that holds the hood.

Here's a little tool that you can use to make a step.. Just a pair of old vice grips w/a tab welded at the end.
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[godspeed]

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Finished sitting on the car
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[jlrussell4]

As I said in the previous post - NICE. Thanks for documenting this. I really like the hand tools approach.

[godspeed]

We needed some more how tooozzzz

[3 Chiefs]

Thanks Ron. That was really nice. You always amaze me at how much work you get done in a short time. I can't imagine you ever sitting on the couch watching TV. I have no doubt you will be driving this car this year.

Paul

[jlrussell4]

We needed some more how tooozzzz:wink:

I agree Ron. Thanks for stepping up. Maybe now that this really bad winter (for you folks north of here ) is over, we'll get some more how tooozzzz.

[Bill Gibson]

Thanks Ron, great stuff. You make it easy to see what happening. Good commentary to go with the great pix ...

[godspeed]

Thanks guys..

I plan on having the car done by ~~ June/July definitaly before oblong The second one soon after that:-)

Depends on the machine shop and motor..(and cash)

[gordsgarage]

The work is amazing Ron, thanks for the play by play. Looks like a person either needs tools or talent. Nice work using budget equipment.

Gord