I have a lot of FRP experience in my past. I would suggest using your glass windshield to make a window surround. Turn it over, mask off all but the outer 1”, and wax and PVA the glass, paint the edge with gel coat. After that FULLY cures, lay up fiberglass around the edge to create a window surround for your main body shell.
You are on the right path and great job of explaining why the body has to be straight to the chassis before the finish work can begin. In essence, you are building a mini-NASCAR race car with a very solid space frame chassis and a relatively flexible body that is only there for aerodynamics and keeping the bugs out of your teeth. You can make a relatively flat surface plane with a large sheet of plywood shimmed on the floor, using a long level. Put the body on that, lay out your assumed center line, and then start measuring and marking on the plywood the key location points. Include measurement of widths of "A" and "C" pillars, door openings, etc. Use plumb bobs, rulers, levels, etc. to make as good an "as is" drawing of the body as it currently stands. You are on track with the asymmetry of the body and having a set of known datum points will help you make the correct decisions as to where to cut and how much to cut in order to get the body back in symmetry. Once you have that, you can then make the decision about whether to fix the existing chopped up body or to make it into a plug to pull a new body from. Having watched the two of you work on this since episode 1, I am more than sure you will come up with an excellent solution that will be both functional and entertaining to watch.
ARRGGG, You've given me a headache! My old Grandpa would say, "it's like putting a windshield wiper on a billy goat's ass...it just won't work. Having built a fiberglass kit car and repaired several fiberglass boats I feel your pain. I have no doubt that you will figure it out. Thanks for taking us along for the ride. 🦟
Personally if you were going to redo the body i would break the body up into 7 sections add a flange to each contacting part then bond it all together again. -Windscreen frame -Roof -Left & right Door frames -Rear lighting panel -Left & right rear side panels This way you can make each part accurately & to conform with your new unibody shell whist making it fit your current doors.
I think its time to use the original body to be condemed ro the roll of plug for a new and improved 21st century body , giving you the style but allowing you to taylor a straight body to the new frame. Keeping in mind the wheel arches have to cover the wheels , you'd be chopping so much around a newly formed shell can be one molded piece and a consistant thickness. Great video as always 🦟
Great episode everyone, one of my reference channels is BuilderCreator with Jay Jarvie. He's an engineer that designed and built his own supercar body from scratch using S-Glass. Lots of composite materials information. Also a cinemagraphic tool tip for you to have fun with different shots is to mount the camera on a thin length of strong wood. Find the balance point for ease of maneuvering it for one person and they are now able to move the camera into tight work zones without needing to have their body in the way or subject to hazards. The pendulum effect of the inertia will also steady the camera making for smooth shots as well. You can do neat "through the car" shots too -just something else to have fun with. Cheers!
GTM coupe doors never fitted well, mine were terrible! And once they have glass in them they fit even worse and as for the door hinges and door flex means you have bigger mountains to climb yet. Front windscreen was intended for the use of a rubber seal .. bonding it just gives you a massive headache. I'd cut the body down the centre, make two identical sides, then make a roof section to join them together.
Well gents you’re in quite the pickle. I’m not an frp master but I’ve been doing bodywork professionally for years. My suggestion is to use your chassis as your reference surface. You know that’s true. Use that as a jig to form the body around. Cut the body into sections that make sense. Like the quarters, tail sections, and roof, then use the chassis as your jig. It will dictate where things need to live. Then you can remold the body into what it needs to be. Best of luck to you lads 😊
I feel your struggle. I like the idea of building a frame for the windshield that can later be shaved back to fit the body even if it seems to be wonky. The glass cannot be modified but the A pillars can be shaped and joined into the cage gradually. The only other idea I can suggest is to look at someone's rusty old Fiat X-1/9 to see how close it might be to your car.
🦟🧩🤔🦟, s-glass with foam core would be so much stronger and lighter, I think that’s the route you have to take. You guys have said repeatedly that you’re going to make this car to the best of your abilities and really haven’t compromised on that. Heck a quarter of the body will be the new fenders, so in for a penny in for a pound.
Before determining how squiff or twisted the body is you NEED to properly mount it to the car as a minimum at bulkhead, the rear of the sills and fully support the boot section. You can see the gaps at the back where it isn't in contact with the rear sills and with the sections that have been cut out it will be floppy as a floppy thing. When we were fitting mine you could alter the door gaps by just raising or lowering the boot. The body was never designed as a structural member. Its just a saggy skin. The gaps around the front screen will likely be taken up with the original rubber too as it looks like the front edge has dropped. As others have mentioned they can deform just sat off the car. Ideally the body needs storing with a wooden frame inside to hold its shape. .. tea and biscuits! 😊
I’m so glad you finished the episode with your realisation that all of the alignments were off due to the accident damage shell. My wife was getting tired of me saying it was the body poorly repaired that was the issue. Would you consider a new body from GTM as it’s likely to be straight? Looking forward to the next installment. Keep up the amazing work.
Good luck guys. Fiberglass nightmare time. I had the same problem with my monte carlo mini shell. Sure the molders get affected by the fumes. A bit of velcro on the top of the door frames stops them flapping at speed. Lots of coat hanger wire, expanding foam, sanding and hard work I got there. And dont give up. Only tips I have for you sorry.😷😵💫
My industrial design college taught that design is a "problem solving" process and you can NOT solve a problem until you, 1st admit you have a problem, and then, 'define' that problem or problems. Their process involved making a diagram of the issues and linking them into a viable set of solutions. We were advised that the best way to hold multiple issues in parallel visibility was by diagraming, because we cannot expect our "mind's eye" to deal with too many variables at once. It's a practical and common sense process. I think you may be on the threshold of that sort of situation.
Hey guys, I like your problem solving! Yes, I think you should build a new body, based on the fixed body you're going to make. If you want to add a bit of the original, as in the "ship" example, go for it! But I think you'll end up with a better product if you build it with new fabric (fiberglass, kevlar, or carbon) laid up in the mold from the fixed "chop-glass" body you have now. But I'd also suggest that whatever decision you make...that will produce the best end result...simply because it is YOUR decision!
I know you are very concentrated in making the car lightweight but I love the recycling side of these restorations/rebuilds. I would say, re-use the body!
Easy job regarding the front screen… PVA the whole screen with at least 2 coats. Let it dry overnight ( non damp area ) a couple of coats of wax then re fiberglass from the inside. It will also stiffen the area around it as it’s probably quite thin . Job done and the screen can then be bonded in . Don’t break the screen!!!!!! I’d probably cover the inside of the A pillar with squirty foam , once cured sand flush then 1 layer of glass over the top . This will then allow for easier trimming for the interior trim to stick to . Make sure the door fit is correct too if you do this . DONT use epoxy it won’t stick to polyester resin ..
Fortunately , you are dealing with fiberglass, which makes the solution very easy . Pull the windscreen out again. Grind all the paint etc back the the fiberglass . Wax the windscreen and place it securely back in the exact position you want it. Then mask the underside, to keep resin from running dripping on everything. Then just lay more fiberglass around the windscreen , making sure that it is able to get under and form the exact platform to adhere it to later.
After reading a bunch of comments. This is my guess. Make a steel frame for the windscreen that is welded to the chassis. Protect the steel chassis with cling wrap, tape, wax or whatever. Cut the shell so the door frames fit the doors. Weld door hinges and latches to the chassis as soon as possible. Start using spray foam to fill all the areas between the cage and the body. Use the foam as a core to fiberglass around. The fiber glassed cores can be bonded to the chassis with 3M panel bonding adhesive. Same goes for the body to the windshield frame flange. The boxed a pillars could be an interior surface. Build the body to the chassis section by section. Winter in a cold garage isn't a great time to make an entire body. I don't see how you could make a new body and not still have to do attachment molding to fit the chassis after making a new body. Just my 2 cents (borrowing from other comments).
🦟 I think you should remove most of the center of the roof out, leaving symmetrical door surrounds, and maybe remove the rear of the body as well so that what remains is straight and square. Then replace the roof skin.
I've seen enough fiberglass builds to say with some degree of confidence that the best way to do this is to get the current body as you want it with bracing to remove the twist and bondo to fill the dips and get it symmetrical then use that as a plug to make a mold for a new body. It's a lot of work. The best example I can think of is the Volvo/Bugatti build on RUclips those guys know what they're doing. Edit: Commented before the end of the video. You've described this process. I believe you won't be happy with it unless you do it properly and given the attention to detail so far it'd be a shame to not do justice to the bodywork for the sake of keeping it original, it's already far from original.
As previously said... For my .02¢ you should trace out the profile of the windshield and add an inch on either side. Run the outline through the bread roller to make a ledge and shape to fit the screen. Now you can measure and weld that to the cage bond the screen to the frame and shape the body to bond onto the remaining flange. Cut what you need to do this and fill what you need etc... Now do the same thing for the doors so you have a metal frame surrounding them and cut/paste the body to fit with good gaps all around fill the roof hole to taste and then do the same to the rear hatch. If you end up with 37, pieces of fiberglass patched together you may want to consider pulling a mold since they will eventually delaminate most assuredly. If it's only 6 pieces you might be able to bond them with enough strength to last. Even if they don't you can still pull a mold! I'm just saying you can relatively easily make 1.5-3" strips with two bends going the length z shape to lock in the profiles and gaps of every hole in the body. I'll also say even with hand layup you could get half the weight in carbon... It might lose some strength of only done a few layers thick but it's really not that structural with all you've built into it. It's jewelry the fabergé on your egg.
Great video, personally I’d keep as much of the shell as possible if only to retain some originality. I don’t know what the French rules are around major component replacement but in the UK you would probably have to put it through limitited type approval as the chassis and body differ from original My other thought is that the body would have been made by eye. And was probably asimertric when it was made. That is certainly the case with my steel chassis Marcos v6. Also, my roof was low to the windscreen but was thin enough to flex upwards during glass installation with me climbing inside and getting my shoulder under the roof whilst the two fitters got the rubber in place
Sounds like fitting the old shell correctly then making a new one from it might be the best option. Even if you bought another (pristine) shell it might not fit either. Don't worry if all it retains is the spirit! 😁👍🦟
🦟Could you make a mirror image of the decent left rear quarter , or so ; and replace the bent right side with that made piece ? Sounds a lot to do though . Best luck
This was made in the 60s with a ruler, plum line and hand tools. Use as much of the car as you can, and fudge the rest. It’s going to look amazing. These cars were never that equal on either side. It’s called human error.
May want to consider making a wooden buck that fits your chassis, then claying the body and make new moulds. It would obviously be significantly more work, but given your desire for detail, this may achieve the outcome you want.
I completely agree with your opinion that modern cars are too fussy. The old fashioned clay model allowed the designers to walk around the project and see it in the real world and keep the design "clean" but today everything has to be done on a computer. The old adage of " if it looks right etc etc" still holds. We all know that you will get there in the end, keep going.
🦟 My tuppence worth to your conundrum regarding the existing GTM body: if you can fix the existing body and modify it for the Mosquito, this would be the quicker and more cost effective route. However, if you then made mould patterns from the body you could build the structure the way you want using modern materials. It would more than double the work, but it would also allow you to replace accident damaged panels (💩 happens!) or make patch panels(?) in future. Just my thoughts as an avid viewer. It’s not my car/time/journey and I look forward to seeing what you do.
As others have said. Cut up original body and create a plug for a mold. Have a watch of builder creator here on RUclips. He’s building a whole composite car and knows his stuff. Also as others have said get some disposable gloves and dust suits because that stuff will make you itch for months.
🦟 oh decisions decisions 😮 keep the body but cut the twist out your thought logic makes perfect sense.. forming a complete new body … !! When 3/4 is there just needs some fetling and be right 👍🏻
Watching you try to fit the windscreen made me think of something else - what will happen for door glass? It doesn't appear there's any room for conventional roll down windows, maybe it will have to have sliding windows, sort of like the original Austin Mini. Besides the body being hand made in the first place, then being pieced together from several different cars after a fire and a couple crashes, I imagine it's possible the body has also deformed somewhat from just laying around unattached to anything. That's the disadvantage of fiberglass, but then on the other hand it's relatively simple to modify. In any case I see an itchy future for you. 🙂
Making a vacuum infused body is almost certainly within the enthusiastic DIYers skillset. The mosquito body shell doesn't have too many large panels so you could probably avoid long resin infusion paths. It would give you options, but is a lot of work and, dare I say it, not hugely RUclips friendly. At least not with a regular video schedule!
Not that easy as it will be a split multi piece mold . That will create problems for sealing the vacuum. Then your mold has to be supported to stop it distorting once the vacuum is applied. Plus you would have to use epoxy not polyester due to the very long infusion time .
@ yeah , infusion isn’t really the problem, it’s the risk of vacuum leaks long infusion times and short pot life. . Making a ‘ quick ‘mold and be lucky not to scrap the first one out is still a £1000 minimum just for the main body section. I would be making a mold for the front and rear sections and using the original as a plug with the modified arches . Been there done that. 😵💫🤭 Would add a nice bit of content for the subscribers though over ye ole winter period.
Carrying that body in and fitting made me think of the power wheels builds that grind hard plumbing use to build but your shell is at least 25% larger than a power wheels body 😆 🦟
The carbonfiber side of things is not as difficult as you think i ran a carbonfiber business up until recently mostly doing motorcycle parts for British superbike teams and the 3 processes, wet lay up is heavier then resin infusion it lighter but prepreg is lighter again but costs a lot more to do so for yourselves i would say resin infusion would work best and easy to do in your workshop without an oven 👍
I do believe the hole for the windscreen is the wrong size and shape for the windscreen! I'd wait until you have sorted out the doors before deciding on making a new body as they are a total nightmare to get to fit.
As you mention singer who “reimagine” Porsches. Why not throw some plastic masking sheet over the chassis, cover it in expanding foam and “reimagining” the mosquito? It could be the MOJITO! Same general shape. A few swags lines added etc. make a one piece shell and then make frames for the doors. And bond them and all other structural parts in then cut the doors out afterwards. IMAGINE THE POSSIBILITIES!!!
the amount of effort that has gone into perfecting all the individual parts of the car, I don't think you would ever be completely satisfied with just repairing this body. because of its age and all the hacked together repairs this body will never be the perfect. and I imagine if you use it then within 2 years of driving the car you would want to take it off and make a new one. so why not just go ahead and make a new one before everything is assembled.
I think I slept through the video where you made and welded brackets for the windshield onto the frame. You did do that already, right? You can't mount the windshield to the floppy body piece, so it's all about mounting it to the frame. Am I missing something? I think you only have one option, and that's to make and install brackets in a few key locations, and then create strips of heavy gauge sheet metal to completely surround the glass and weld all of those pieces to each other. Because you were doing it in this video already, I didn't mention that you need to center the windshield and get it as close as possible to where it should go in relation to the body by eyeballing it. After all of the above is done, you modify the body, or make a completely new body part, that matches the contours and fits properly around the windshield. Anyway, you two have not needed my advice before this, and I'm sure that you don't need it now because you have done fantastic work so far. I'm sure that no matter what you do, it will be great.
Just make a new body and keep the old one, as a primal. You will anyway have to create wheel arches, so in the end, it will not have to do with the original, especiall as you are also go to use your very much loved head lights😂
Correct and modify the original make it your own and stronger and then mould off it and you will end up with a better, lighter, stronger, nearly perfect body.
Make a new body you really wouldn't be saving anything of value, it's been destroyed and repaired and honestly no amount of work will make it right you would be building upon a hack job hoping for the best. Then with a new body it would be single piece properly formed and built to suit
But will you be able to take the fiberglass body off the frame after having the windshield installed, withoutthe risk of braking it? Would it be possible to create a windshield frame welded on the chassi and then fit the body above the whole thing?
🦟 I would say make a new body, there must be changed so many things, wheelarches, roof and so on Its easier, lighter and faster in my opinion to use the old body as a plug to make a new one
I have said from the beginning to use that shell as a plug to make a mold, this way you can fix all the errors and use anything you want to, in other words a new body... 🦟🦟🦟🦟🦟
I think like the other people here, although I have no experience at all, that you maybe need to make a complete new body maybe using the old one once correct as a mold. I think that is what Andrew already said in the video. Do you know the saying * I learn something every day * well I do watching this channel. thank you . 🦟🦟🦟🦟🦟🦟🦟🦟🦟🦟🦟🦟
to be honest i think your over thinking it at the end of the day its fiberglass you can make it whatever shape you want it to be .if its a high spot add more fiberglass to the inside of the body if its low add extra to the top of the body as long as you roughen it up and clean with acetone before you attach it to the body then youll be fine. Throw it on then shape to the correct measurements afterwards. seriusly your over thinking it. for your windscreen surround insulation tape on the back of the windscreenbut cover all of the windscreen then pencil a line where you need the body to support it then you can build the frame for it to sit on" once cured. peel off" then resin that to the body. Wear sleves and gloves and masks its really ichy stuff. ive done a lot of fiberglass. Seriously your over thinking it. youll soon get the hang of it it aint that hard
You are going to learn real quick about fiberglass itch. Seriously , Ill bet you find it in your undies when you get in the shower. That job should be done outside, you will be trying to get rid of that dust for months. Best thing for cutting fiberglass is a saw, that I cant think of the correct name for, anyway the type you would use to remove plaster from a broken arm . One that the blade only moves a millimeter back and forth. One that you can touch the blade whilst its going without cutting yourself, because it only cuts rigid objects. By using this type of saw the dust just falls to the ground and doesnt get spread everywhere. The only further advice I can give you now, and its probably too late , is cold shower. A hot shower will open the pours of your skin letting the dust in. You wont ever get it out of a woolen jumper. Correct attire is basically a complete vinyl covering.
In my humble opinion, I think you'll be more satisfied if you correct the existing body irregularities and use it as a buck to create a mold for a new body. In correcting the discrepancies you can use additional material to make it stronger and less likely to flex. Having it solidly attached to the chassis, while building the mold, will insure that the new, correct, body will be straight. 🦟🦟🦟
🦟, seems like a lot of head ache. If you get new body, will it fit perfect to your chassis? I think you need to make your body to your quality you seeks. I'm watching to see what nightmare scenario I will be encountering when I build mine.
I think you won't be sorry if you made your own body, even if you made a completely different body for your car, I wouldn't be disappointed - your framework is solid! 🦟🦟🦟
Great video as always ! :) I guess you can keep the front shell and the back end as is. About the middle section of the car : It almost looks like doing the body from scratch will get you the symmetry and reliable body placement you are looking for. It is possible to correct the existing body, but will it be faster ? Will it really be symmetrical ? And more importantly, will it fits your state of mind better ? IMHO, I have the feeling you guys favor precision over everything, and doing the doors, roof and pillar from scratch based on the chassis instead of the body shell might be the solution that will fit better your ethic and give you the satisfaction you are looking for :) But it's your project, you do you ! Great job ! :)
I have a lot of FRP experience in my past. I would suggest using your glass windshield to make a window surround. Turn it over, mask off all but the outer 1”, and wax and PVA the glass, paint the edge with gel coat. After that FULLY cures, lay up fiberglass around the edge to create a window surround for your main body shell.
I have zero FRP experience. This sounds like a great method. (how's that for worthless internet opinion? :-D )
You are on the right path and great job of explaining why the body has to be straight to the chassis before the finish work can begin. In essence, you are building a mini-NASCAR race car with a very solid space frame chassis and a relatively flexible body that is only there for aerodynamics and keeping the bugs out of your teeth.
You can make a relatively flat surface plane with a large sheet of plywood shimmed on the floor, using a long level. Put the body on that, lay out your assumed center line, and then start measuring and marking on the plywood the key location points. Include measurement of widths of "A" and "C" pillars, door openings, etc. Use plumb bobs, rulers, levels, etc. to make as good an "as is" drawing of the body as it currently stands. You are on track with the asymmetry of the body and having a set of known datum points will help you make the correct decisions as to where to cut and how much to cut in order to get the body back in symmetry. Once you have that, you can then make the decision about whether to fix the existing chopped up body or to make it into a plug to pull a new body from.
Having watched the two of you work on this since episode 1, I am more than sure you will come up with an excellent solution that will be both functional and entertaining to watch.
ARRGGG, You've given me a headache! My old Grandpa would say, "it's like putting a windshield wiper on a billy goat's ass...it just won't work. Having built a fiberglass kit car and repaired several fiberglass boats I feel your pain. I have no doubt that you will figure it out. Thanks for taking us along for the ride. 🦟
Can't wait to see the finished fenders
Personally if you were going to redo the body i would break the body up into 7 sections add a flange to each contacting part then bond it all together again.
-Windscreen frame
-Roof
-Left & right Door frames
-Rear lighting panel
-Left & right rear side panels
This way you can make each part accurately & to conform with your new unibody shell whist making it fit your current doors.
I think its time to use the original body to be condemed ro the roll of plug for a new and improved 21st century body , giving you the style but allowing you to taylor a straight body to the new frame. Keeping in mind the wheel arches have to cover the wheels , you'd be chopping so much around a newly formed shell can be one molded piece and a consistant thickness. Great video as always 🦟
The path forward is clear....get an English Wheel and make an alloy body! 🦟🦟🦟🦟🦟
Good morning from South Africa....NEVER trust the hole, LOL
As for the lumps....
Great episode everyone, one of my reference channels is BuilderCreator with Jay Jarvie. He's an engineer that designed and built his own supercar body from scratch using S-Glass. Lots of composite materials information. Also a cinemagraphic tool tip for you to have fun with different shots is to mount the camera on a thin length of strong wood. Find the balance point for ease of maneuvering it for one person and they are now able to move the camera into tight work zones without needing to have their body in the way or subject to hazards. The pendulum effect of the inertia will also steady the camera making for smooth shots as well. You can do neat "through the car" shots too -just something else to have fun with. Cheers!
For reference of Fiberglass weight, see 80's corvettes...
GTM coupe doors never fitted well, mine were terrible! And once they have glass in them they fit even worse and as for the door hinges and door flex means you have bigger mountains to climb yet. Front windscreen was intended for the use of a rubber seal .. bonding it just gives you a massive headache. I'd cut the body down the centre, make two identical sides, then make a roof section to join them together.
Love it!! The joys of building and owning a cool old/new car!! You guys are legends. 🦟
Well gents you’re in quite the pickle. I’m not an frp master but I’ve been doing bodywork professionally for years. My suggestion is to use your chassis as your reference surface. You know that’s true. Use that as a jig to form the body around. Cut the body into sections that make sense. Like the quarters, tail sections, and roof, then use the chassis as your jig. It will dictate where things need to live. Then you can remold the body into what it needs to be. Best of luck to you lads 😊
I feel your struggle. I like the idea of building a frame for the windshield that can later be shaved back to fit the body even if it seems to be wonky. The glass cannot be modified but the A pillars can be shaped and joined into the cage gradually. The only other idea I can suggest is to look at someone's rusty old Fiat X-1/9 to see how close it might be to your car.
🦟🧩🤔🦟, s-glass with foam core would be so much stronger and lighter, I think that’s the route you have to take. You guys have said repeatedly that you’re going to make this car to the best of your abilities and really haven’t compromised on that. Heck a quarter of the body will be the new fenders, so in for a penny in for a pound.
Before determining how squiff or twisted the body is you NEED to properly mount it to the car as a minimum at bulkhead, the rear of the sills and fully support the boot section. You can see the gaps at the back where it isn't in contact with the rear sills and with the sections that have been cut out it will be floppy as a floppy thing. When we were fitting mine you could alter the door gaps by just raising or lowering the boot. The body was never designed as a structural member. Its just a saggy skin. The gaps around the front screen will likely be taken up with the original rubber too as it looks like the front edge has dropped.
As others have mentioned they can deform just sat off the car. Ideally the body needs storing with a wooden frame inside to hold its shape. .. tea and biscuits! 😊
Loved the episode. Maybe take some templates of the doors to make sure they are identical too.
I’m so glad you finished the episode with your realisation that all of the alignments were off due to the accident damage shell. My wife was getting tired of me saying it was the body poorly repaired that was the issue.
Would you consider a new body from GTM as it’s likely to be straight?
Looking forward to the next installment. Keep up the amazing work.
I am so glad to see the start of the body work! I look forward to all of the problem solving soon. 🦟
Those handprints on Andrew's pants at the end of the video. Almost look like a prank. Thanks for another video, cheers
Good luck guys. Fiberglass nightmare time. I had the same problem with my monte carlo mini shell. Sure the molders get affected by the fumes. A bit of velcro on the top of the door frames stops them flapping at speed. Lots of coat hanger wire, expanding foam, sanding and hard work I got there. And dont give up. Only tips I have for you sorry.😷😵💫
My industrial design college taught that design is a "problem solving" process and you can NOT solve a problem until you, 1st admit you have a problem, and then, 'define' that problem or problems. Their process involved making a diagram of the issues and linking them into a viable set of solutions. We were advised that the best way to hold multiple issues in parallel visibility was by diagraming, because we cannot expect our "mind's eye" to deal with too many variables at once. It's a practical and common sense process. I think you may be on the threshold of that sort of situation.
The EXPERIENCE this time ... WONKY or not stayed, 100% humble. You guys rule!! 🦟🦟🦟🦟
Hey guys, I like your problem solving! Yes, I think you should build a new body, based on the fixed body you're going to make. If you want to add a bit of the original, as in the "ship" example, go for it! But I think you'll end up with a better product if you build it with new fabric (fiberglass, kevlar, or carbon) laid up in the mold from the fixed "chop-glass" body you have now. But I'd also suggest that whatever decision you make...that will produce the best end result...simply because it is YOUR decision!
Thanks!
Thanks Matthew!
I know you are very concentrated in making the car lightweight but I love the recycling side of these restorations/rebuilds. I would say, re-use the body!
Easy job regarding the front screen…
PVA the whole screen with at least 2 coats. Let it dry overnight ( non damp area ) a couple of coats of wax then re fiberglass from the inside.
It will also stiffen the area around it as it’s probably quite thin . Job done and the screen can then be bonded in .
Don’t break the screen!!!!!!
I’d probably cover the inside of the A pillar with squirty foam , once cured sand flush then 1 layer of glass over the top . This will then allow for easier trimming for the interior trim to stick to . Make sure the door fit is correct too if you do this .
DONT use epoxy it won’t stick to polyester resin ..
Fortunately , you are dealing with fiberglass, which makes the solution very easy . Pull the windscreen out again. Grind all the paint etc back the the fiberglass . Wax the windscreen and place it securely back in the exact position you want it. Then mask the underside, to keep resin from running dripping on everything. Then just lay more fiberglass around the windscreen , making sure that it is able to get under and form the exact platform to adhere it to later.
After reading a bunch of comments. This is my guess.
Make a steel frame for the windscreen that is welded to the chassis. Protect the steel chassis with cling wrap, tape, wax or whatever. Cut the shell so the door frames fit the doors. Weld door hinges and latches to the chassis as soon as possible. Start using spray foam to fill all the areas between the cage and the body. Use the foam as a core to fiberglass around. The fiber glassed cores can be bonded to the chassis with 3M panel bonding adhesive. Same goes for the body to the windshield frame flange. The boxed a pillars could be an interior surface. Build the body to the chassis section by section. Winter in a cold garage isn't a great time to make an entire body. I don't see how you could make a new body and not still have to do attachment molding to fit the chassis after making a new body. Just my 2 cents (borrowing from other comments).
Milestone Episode ! Really looking forward to the body work! 🦟🦟🦟
Really lookin forward to seeing the completed body.
🦟 I think you should remove most of the center of the roof out, leaving symmetrical door surrounds, and maybe remove the rear of the body as well so that what remains is straight and square. Then replace the roof skin.
I've seen enough fiberglass builds to say with some degree of confidence that the best way to do this is to get the current body as you want it with bracing to remove the twist and bondo to fill the dips and get it symmetrical then use that as a plug to make a mold for a new body. It's a lot of work. The best example I can think of is the Volvo/Bugatti build on RUclips those guys know what they're doing.
Edit: Commented before the end of the video. You've described this process. I believe you won't be happy with it unless you do it properly and given the attention to detail so far it'd be a shame to not do justice to the bodywork for the sake of keeping it original, it's already far from original.
As previously said... For my .02¢ you should trace out the profile of the windshield and add an inch on either side. Run the outline through the bread roller to make a ledge and shape to fit the screen. Now you can measure and weld that to the cage bond the screen to the frame and shape the body to bond onto the remaining flange. Cut what you need to do this and fill what you need etc... Now do the same thing for the doors so you have a metal frame surrounding them and cut/paste the body to fit with good gaps all around fill the roof hole to taste and then do the same to the rear hatch. If you end up with 37, pieces of fiberglass patched together you may want to consider pulling a mold since they will eventually delaminate most assuredly. If it's only 6 pieces you might be able to bond them with enough strength to last. Even if they don't you can still pull a mold! I'm just saying you can relatively easily make 1.5-3" strips with two bends going the length z shape to lock in the profiles and gaps of every hole in the body. I'll also say even with hand layup you could get half the weight in carbon... It might lose some strength of only done a few layers thick but it's really not that structural with all you've built into it. It's jewelry the fabergé on your egg.
Yusssss. I have been looking forward to this episode 😊
Great video, personally I’d keep as much of the shell as possible if only to retain some originality. I don’t know what the French rules are around major component replacement but in the UK you would probably have to put it through limitited type approval as the chassis and body differ from original
My other thought is that the body would have been made by eye. And was probably asimertric when it was made. That is certainly the case with my steel chassis Marcos v6. Also, my roof was low to the windscreen but was thin enough to flex upwards during glass installation with me climbing inside and getting my shoulder under the roof whilst the two fitters got the rubber in place
Sounds like fitting the old shell correctly then making a new one from it might be the best option. Even if you bought another (pristine) shell it might not fit either. Don't worry if all it retains is the spirit! 😁👍🦟
🦟Love your work guys !
Good luck with making that body fit, it's jobs like that I really hate, I'd be contemplating ditching it and making it an exo car 🦟
🦟Could you make a mirror image of the decent left rear quarter , or so ; and replace the bent right side with that made piece ? Sounds a lot to do though . Best luck
This was made in the 60s with a ruler, plum line and hand tools. Use as much of the car as you can, and fudge the rest. It’s going to look amazing. These cars were never that equal on either side. It’s called human error.
This going to be scary fast possibly super car killer
🦟🦟🦟🦟🦟🦟🦟 I love you`re work. Seeing the body rebuilt in S-glass would be awesome. have yo thought of doing the windscreen flange in steel?
Always Great
May want to consider making a wooden buck that fits your chassis, then claying the body and make new moulds.
It would obviously be significantly more work, but given your desire for detail, this may achieve the outcome you want.
I completely agree with your opinion that modern cars are too fussy. The old fashioned clay model allowed the designers to walk around the project and see it in the real world and keep the design "clean" but today everything has to be done on a computer. The old adage of " if it looks right etc etc" still holds. We all know that you will get there in the end, keep going.
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My tuppence worth to your conundrum regarding the existing GTM body: if you can fix the existing body and modify it for the Mosquito, this would be the quicker and more cost effective route. However, if you then made mould patterns from the body you could build the structure the way you want using modern materials. It would more than double the work, but it would also allow you to replace accident damaged panels (💩 happens!) or make patch panels(?) in future.
Just my thoughts as an avid viewer. It’s not my car/time/journey and I look forward to seeing what you do.
As others have said. Cut up original body and create a plug for a mold. Have a watch of builder creator here on RUclips. He’s building a whole composite car and knows his stuff. Also as others have said get some disposable gloves and dust suits because that stuff will make you itch for months.
Nice project 🦟
🦟 oh decisions decisions 😮 keep the body but cut the twist out your thought logic makes perfect sense.. forming a complete new body … !! When 3/4 is there just needs some fetling and be right 👍🏻
Watching you try to fit the windscreen made me think of something else - what will happen for door glass? It doesn't appear there's any room for conventional roll down windows, maybe it will have to have sliding windows, sort of like the original Austin Mini.
Besides the body being hand made in the first place, then being pieced together from several different cars after a fire and a couple crashes, I imagine it's possible the body has also deformed somewhat from just laying around unattached to anything. That's the disadvantage of fiberglass, but then on the other hand it's relatively simple to modify. In any case I see an itchy future for you. 🙂
With panel gaps like that, you might as well slap a Tesla badge on it 😁
Maybe my fav episode. 🦟🦟🦟
Love This channel.
It would be interesting to see if a new shell and doors from Hambly would improve things... I suspect not 🤷🏻♂️
Great video, is it better to make a completely new body, and cut out the right messurements or is making a new body a big job 😊
Making a vacuum infused body is almost certainly within the enthusiastic DIYers skillset. The mosquito body shell doesn't have too many large panels so you could probably avoid long resin infusion paths. It would give you options, but is a lot of work and, dare I say it, not hugely RUclips friendly. At least not with a regular video schedule!
Not that easy as it will be a split multi piece mold .
That will create problems for sealing the vacuum.
Then your mold has to be supported to stop it distorting once the vacuum is applied.
Plus you would have to use epoxy not polyester due to the very long infusion time .
@newagetemplar6100 yeah, everything you say is correct, it's not straightforward. However these guys are hardly afraid of a challenge!
@ yeah , infusion isn’t really the problem, it’s the risk of vacuum leaks long infusion times and short pot life. .
Making a ‘ quick ‘mold and be lucky not to scrap the first one out is still a £1000 minimum just for the main body section.
I would be making a mold for the front and rear sections and using the original as a plug with the modified arches .
Been there done that. 😵💫🤭
Would add a nice bit of content for the subscribers though over ye ole winter period.
64 Camaro rear lights would look good on this.
Carrying that body in and fitting made me think of the power wheels builds that grind hard plumbing use to build but your shell is at least 25% larger than a power wheels body 😆 🦟
The carbonfiber side of things is not as difficult as you think i ran a carbonfiber business up until recently mostly doing motorcycle parts for British superbike teams and the 3 processes, wet lay up is heavier then resin infusion it lighter but prepreg is lighter again but costs a lot more to do so for yourselves i would say resin infusion would work best and easy to do in your workshop without an oven 👍
I do believe the hole for the windscreen is the wrong size and shape for the windscreen! I'd wait until you have sorted out the doors before deciding on making a new body as they are a total nightmare to get to fit.
Your Door fitting escapades with Body Snatcher did come up. Ive got a plan for that
Another great episode, thanks guys. 🦟
As you mention singer who “reimagine” Porsches. Why not throw some plastic masking sheet over the chassis, cover it in expanding foam and “reimagining” the mosquito? It could be the MOJITO! Same general shape. A few swags lines added etc. make a one piece shell and then make frames for the doors. And bond them and all other structural parts in then cut the doors out afterwards. IMAGINE THE POSSIBILITIES!!!
the amount of effort that has gone into perfecting all the individual parts of the car, I don't think you would ever be completely satisfied with just repairing this body. because of its age and all the hacked together repairs this body will never be the perfect. and I imagine if you use it then within 2 years of driving the car you would want to take it off and make a new one. so why not just go ahead and make a new one before everything is assembled.
I think I slept through the video where you made and welded brackets for the windshield onto the frame. You did do that already, right?
You can't mount the windshield to the floppy body piece, so it's all about mounting it to the frame.
Am I missing something? I think you only have one option, and that's to make and install brackets in a few key locations, and then create strips of heavy gauge sheet metal to completely surround the glass and weld all of those pieces to each other. Because you were doing it in this video already, I didn't mention that you need to center the windshield and get it as close as possible to where it should go in relation to the body by eyeballing it.
After all of the above is done, you modify the body, or make a completely new body part, that matches the contours and fits properly around the windshield.
Anyway, you two have not needed my advice before this, and I'm sure that you don't need it now because you have done fantastic work so far. I'm sure that no matter what you do, it will be great.
Just make a new body and keep the old one, as a primal. You will anyway have to create wheel arches, so in the end, it will not have to do with the original, especiall as you are also go to use your very much loved head lights😂
Correct and modify the original make it your own and stronger and then mould off it and you will end up with a better, lighter, stronger, nearly perfect body.
Easy composites are a good source composites work here on yt.
🎉🎉🎉
Make a new body you really wouldn't be saving anything of value, it's been destroyed and repaired and honestly no amount of work will make it right you would be building upon a hack job hoping for the best. Then with a new body it would be single piece properly formed and built to suit
But will you be able to take the fiberglass body off the frame after having the windshield installed, withoutthe risk of braking it? Would it be possible to create a windshield frame welded on the chassi and then fit the body above the whole thing?
In comment of materials, polyester resin shrinks on cureing, epoxy just sets.
I was enthralled waiting to see how you sorted this out. Well done to you both. 🦟
Hello I think you should make what makes sens you have the knowledge to make it right
🦟 I would say make a new body, there must be changed so many things, wheelarches, roof and so on
Its easier, lighter and faster in my opinion to use the old body as a plug to make a new one
Mosquito 🦟
Is it possible that what you have built isn't a GTM chassis, mechanicals or drive train and so maybe doesn't have to have a GTM body?
All things considered, you would most likely be better off making a new body that way you'd better placed to correct the problems of its past
Buzz buzz 🦟
🇧🇷👏🏾👏🏾👏🏾👏🏾
Parabéns
New
Have you seen someone is giving away a set of body panels on FB?
GTM kit cars group.
I've seen it but it would cost as much to go and collect as the one I have will cost to sort
I have said from the beginning to use that shell as a plug to make a mold, this way you can fix all the errors and use anything you want to, in other words a new body... 🦟🦟🦟🦟🦟
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Been waiting on this part. 🦟🦟🦟🦟🦟
New body and make it lighter and stronger, the old one is just crap
I think like the other people here, although I have no experience at all, that you maybe need to make a complete new body maybe using the old one once correct as a mold. I think that is what Andrew already said in the video. Do you know the saying * I learn something every day * well I do watching this channel. thank you . 🦟🦟🦟🦟🦟🦟🦟🦟🦟🦟🦟🦟
It won't be original, but at this point what is original? If you make new it will be lighter and probably stronger.
to be honest i think your over thinking it at the end of the day its fiberglass you can make it whatever shape you want it to be .if its a high spot add more fiberglass to the inside of the body if its low add extra to the top of the body as long as you roughen it up and clean with acetone before you attach it to the body then youll be fine. Throw it on then shape to the correct measurements afterwards. seriusly your over thinking it. for your windscreen surround insulation tape on the back of the windscreenbut cover all of the windscreen then pencil a line where you need the body to support it then you can build the frame for it to sit on" once cured. peel off" then resin that to the body. Wear sleves and gloves and masks its really ichy stuff. ive done a lot of fiberglass. Seriously your over thinking it. youll soon get the hang of it it aint that hard
You are going to learn real quick about fiberglass itch. Seriously , Ill bet you find it in your undies when you get in the shower. That job should be done outside, you will be trying to get rid of that dust for months. Best thing for cutting fiberglass is a saw, that I cant think of the correct name for, anyway the type you would use to remove plaster from a broken arm . One that the blade only moves a millimeter back and forth. One that you can touch the blade whilst its going without cutting yourself, because it only cuts rigid objects. By using this type of saw the dust just falls to the ground and doesnt get spread everywhere. The only further advice I can give you now, and its probably too late , is cold shower. A hot shower will open the pours of your skin letting the dust in. You wont ever get it out of a woolen jumper. Correct attire is basically a complete vinyl covering.
In my humble opinion, I think you'll be more satisfied if you correct the existing body irregularities and use it as a buck to create a mold for a new body. In correcting the discrepancies you can use additional material to make it stronger and less likely to flex. Having it solidly attached to the chassis, while building the mold, will insure that the new, correct, body will be straight. 🦟🦟🦟
Make a new one
Keep some originality.
🦟, seems like a lot of head ache. If you get new body, will it fit perfect to your chassis? I think you need to make your body to your quality you seeks.
I'm watching to see what nightmare scenario I will be encountering when I build mine.
I think you won't be sorry if you made your own body, even if you made a completely different body for your car, I wouldn't be disappointed - your framework is solid! 🦟🦟🦟
🦟 Make a new body. A very entertaining episode
I was going to joke about making a fully carbon body and then you actually mentioned it 😂 🦟
I think you should try to keep as much of the original shell as possible, good luck.🦟
Great video as always ! :)
I guess you can keep the front shell and the back end as is.
About the middle section of the car :
It almost looks like doing the body from scratch will get you the symmetry and reliable body placement you are looking for.
It is possible to correct the existing body, but will it be faster ? Will it really be symmetrical ? And more importantly, will it fits your state of mind better ?
IMHO, I have the feeling you guys favor precision over everything, and doing the doors, roof and pillar from scratch based on the chassis instead of the body shell might be the solution that will fit better your ethic and give you the satisfaction you are looking for :)
But it's your project, you do you !
Great job ! :)