Posted by: kdavis

A quick update on my progress. These doors have been an absolute pain. The profiles were completely off, and then thanks to me overtrimming the door edges, and then doing the rolled edges, it was a trifecta of difficult body work.

BUT…I’m finally done with them, at least until slick sand. On an MK3.1, you’re basically doing sculpture, as I’ve said before, so lots of rage gold build up, fiberglass work, and sanding, and then sculpting all of the profiles.

I still need to take the body back off, and at that time, I’ll build up the rolled edges a bit more where the door and dash meet. There’s probably an 1/8″ difference in thickness, and I’d like that to match. So, I’ll have to do a gradual build out into the door.

On my rolled edges where the doors and dash meet, I was a little concerned with the strength, despite my best effort to break them off with a mallet (testing to see how they were), so I ended up adding a layer of glass in there to give it a little more rigidity. From others that have done it, it seems like it’ll last pretty well.

I ended up buying some of the cheap harbor freight car dollies, and they work very well, considering the price. It’s still a 2200lb car, but easier to move it around the the shop now.







Body Work Part 37

   Posted by: kdavis

It’s been quite a while since I’ve done an update, mainly because there really hasn’t been a lot of activity in the build. Over the last several months, I’ve started a new business, a detailing company, so things have been pretty busy for me, leaving far less time to work on the car.

But, in the last few weeks, I’ve found the bug and the time to get back to the car and get busy on the body work.

Rather than chronicle what I’ve been doing week by week or month by month, it’s probably better to just highlight some stuff and bring things up to speed for where the car sits right now.

Current Status:

As of today, the body is back on the chassis, doors, trunk, and hood are hung, and I’m doing the final fitting and filling to get all of the gaps correct, lines aligned, and panels smooth. I have some more work to do on the rolled cockpit edges, and the rolled door edges, specifically where the doors meet the bulkhead and the dash. The rest of the body is sanded to a point where a small skim coat should get us ready to shoot featherfill and block sand before primer. The doors and trunk are probably the parts that need the most work.

Hidden Body Mounts:

I went back and forth on my hidden body mount systems, and in the end, I think I have basically abandoned all of my hidden body mount plans. I made side and rear hidden body mounts and bonded them to the body using the standard HSRF. This turns out to be a pretty epic fail as all of the side mounts and 2 of the rear mounts literally popped off when we put the body on. After closer inspection, it turns out that it was more of a procedural issue than a materials one. I think if I were to redo it, I would drill through the body on all of them with a few rivets to hold them in place by going from the inside of the body to the outside, then trimming the back end of the rivet and filling over the holes. I’d probably also throw some fiberglass on top of it for extra security.

That all being said, I am now only going to do side hidden body mounts. I’m going to either go back to Quick Jacks in the rear, or possibly button heads.

Hood Vents and Rivet on Hood Scoop and Extension:

These hood vents are a lot of work, no doubt about it. I essentially cut 2 huge holes in my hood, and I’m trying to make it look like the vents are supposed to be there. Not surprisingly, that’s not easy, and requires some creativity and sculpting with body filler. So far, it’s going well, and with a little more loving care, the hood will look awesome, and unique as there aren’t a lot of cars running these.

Trunk Lid with Hidden Hinges:

I love the Breeze hidden trunk hinges! As with the hood vents, to make them work, it requires some sculpting so they all look right. I really like how they turned out, and they look like they came that way. I need to do a little more tweaking to get the gaps correct, but it looks great!






Additional News:

I decided to buy a burned Mark 2 car from a guy in California. It has a tricked out 347ci engine with stacked injection, and some other cool little tidbits I want to steal for my 3.1. At this point, the plan is to take both cars, make one ultra awesome car that I’ll keep and one really awesome car to sell to someone else. Of course, just like anyone else, I’ll have to keep the best goodies for myself. ;-> I’ll pick up the car on August 10th, and will chronicle the rebuild process here in tandem with my 3.1 build. I’m pretty stoked about it, and have already started collecting parts.