Bread loaf, sort of...

[angib]

It's no problem to widen the end caps - cut them in the middle and the extra bit you have to add will just be simple (not double, or spherical) curvature.

The designer of my Morris Minor decided very shortly before production that it was too narrow and they widened the car 4" down the middle like this - you can just see in the middle of the bonnet/hood where they decided not to blend the widening in, but everywhere else they just smoothed to two sides together.



Very early models have a patch in the middle of the bumpers as they had already made those press moulds and so they cut and joined early bumpers!

[Rusty O'Toole]

Hi Rusty,

The templates I was referring to are the end cap and rear corners.

I understand the use of templates to check the profile from side to side.

The issue with making the body wider is that the end cap(s) will no longer be the same profile.
It is difficult to see in the pictures, but the compound curve goes all the way across the front cap, no part of it is flat.

The rear corners were cut from a similar rear cap, it too has no "flat" sections.
So, if I create a wider body, the existing metal isn't of use for patterns.

Does all that make sense?
I'm figuring I'll have to make the new wood frame, then cover it with something so I have a base for the fiberglass.
If I go with metal, the wood framework should be enough.

The really good news is that I have refined the interior layout so that everything I want fits within a 16' body.
The original was 19' long and didn't have half of what I'm going to put in there!

Rob

I see. The tricky part is in making the body 12" wider.

I have done similar work in modifying old cars such as, chopping the top or building a stretch.

In your case I would probably cut the front cap in 3 pieces, making the cuts a few inches inboard of the running lights. Then splice in 6" wide pieces. This could be done by welding but would be easler to just fasten the pieces to a wooden framework, fill the gaps and smooth with plaster, then make a mold and mold a 1 piece fibreglass end cap.



The back would be a cinch. Just move the sides apart and make the rear window 12" wider.

It appears from the photos that the original roof was made in pieces with seams in between.

Your roof could be framed with wood and covered with sheet fibreglas with the end cap and back corners made separately.

If you knew how you were going to do this it would be simple to add a lip or flange to the molded pieces, for the roof sheet to fit into. Then bond them together or screw them together with some kind of sealant. I have a Master Coach motor home with fibreglass roof. Will have to go out and see how they handled it, but if you can get a look at a trailer or motor home with fibreglass body or roof it may give you some ideas.

[48Rob]

Andrew,

Good thing they decided to make the car a little wider...it looks small enough widened!

Thank you for your thoughts.

I thought about "just adding a strip", but there is enough curve that I think the strip would have to be formed to match the rest.
Tough to see in the picture, but the roof doesn't flatten out until it hits the window area.

<img src="http://im1.shutterfly.com/media/47a1ce30b3127ccefe02dc47bcc700000030O02AbNGjdu5bMge3nww/cC/f%3D0/ps%3D50/r%3D0/rx%3D720/ry%3D480/">

Rusty,

Thank you.

The front and rear caps were two piece affairs, with a left and right.
Then solid panels were used in between the end caps, with seams running from side to side.

The rear corners were cut from a cap that was "one piece" like the front.
I did this to determine if the center section was "flat" or compound.
It turned out to be compound.

I considered how to make fiberglass caps and metal center pieces, and came up with the thought of embedding an aluminum strip in the end of each of the caps so I could screw it all together.
My current thought is to make the roof from whatever material, or a combination so it is waterproof on its own, then cover it with doped canvas for the authentic look without the worry of leaks.

Rob

[wagondude]

I would be interested in your floor plan. With all the stuff my wife thinks she wants, I can't see how I would manage to do anything in less than 16'. You might be able to solve the issue of the compound curves with foam. Just carve and sand to shape then cover with 'glass or canvas.

Bill

[dodgedartgt]

Hi Rob.

I'm a relative newbie on here, leastwise, been a lurker for a while. I second the last post about seeing your 16ft interior lay out. Anyhow, I've just seen this post for the first time (I have seen some of oyur website previously), its been over a year since the last post. Has there been any progress?

If you want to replicate the front and rear caps in metal (steel OR aluminum), then do yourself a favor and have a look at the forums at Metal Meet, http://www.metalmeet.com/forum/index.php If you post the story over there, I'm sure the will be many people offering sound advice on shaping the panels. Just take a look at some of the members projects, like hand built art deco style cars, etc...

Mike in FL

[48Rob]

Mike,

Thank you for the tips.
I did join one of the metal working forums and got a lot of good advice.
The project has been put on long term hold as we are helping our daughter raise her two little boys.
They are a lot of fun to have living with us, but time and money have become short.

Maybe some day.

Rob