Step 2 in making your own tailpiece

Ok so first time I ever do this so I am bound to make mistakes!

Heres a few more pics

Pic 1

Rough shape

Rough shape

Started shaping the ‘thing’ by cutting an angle in the front and rear with a hacksaw

Pic 2

Rough shape rear view

Rough shape rear view

thing from a different angle

Pic 3

Wet foam

Wet foam

The filler foam has not completely set (more than 12 hours later!

Pic 4

Rough shape on bike

Rough shape on bike

Testing the shape on the bike

Pics 5,6,7,8

Starting to look like something extra foam added

Starting to look like something extra foam added

Starting to look like something extra foam added side view

Starting to look like something extra foam added side view

Starting to look like something extra foam added front view

Starting to look like something extra foam added front view

Yet another picture of extra foam added

Yet another picture of extra foam added

Batteries on the camera conked out so alot of shaping got done in between, decided I wanted to round the tail more so added more foam to get a single uninterrupted curve

Pics 9, 10, 11

Nearly completed shape on bike

Nearly completed shape on bike

Nearly completed shape on bike from another angle

Nearly completed shape on bike from another angle

Nearly completed shape on bike again from another angle

Nearly completed shape on bike again from another angle

Got some nice shape into the tail and checking it on the bike

Pic 12

Ready for laying of fibreglass

Ready for laying of fibreglass

little things on the front are an afterthought to extend the tail piece under the seat and make a smoother transition, getting ready to lay fibreglass

Pics 13, 14, 15

Ugly dip

Ugly dip

Ugly dip

Ugly dip

Ugly dip

Ugly dip

Grrrrr…. fibreglass resin eats away at the polystyrene, literally melting away all my hard work on shaping the tail, added to which I ran out of resin, talk about forward planning! now i need more resin, and probably going to have to build up the dips with body filler.

On the bright side, because of the foam and surviving polystyrene the tail piece is so stiff i was tempted to stand on it cos it felt so strong. And that with 1 layer of fibreglass!!

I have since started correcting the shape and added more fibreglass.

Posted under SR 500 Project Bike

This post was written by Shaun on June 24, 2009

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Falcon SOLD

Ho-hum, so the realisation set in that I could not have finished the Ford that I bought on auction.

Finances and the fact that I no longer have a bakkie, mean that it would have been difficult  to get anything right.

So it was with a heavy heart that I put it up for sale, hoping that someone could get good use out of my failed project.

Sheraz bought the car from me an picked it up on Monday the 2nd of March.

So, so sad

Posted under Project Falcon

This post was written by Shaun on March 4, 2009

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Project Falcon Part 1

So heres the story, a few months (yes months!) ago I had a Wednesday off and decided to go to an auction at SMD. Now the auctions at SMD are for accident damaged cars (mostly), so i was hoping to see the prices of cars so that when I had the time and the money I could get myself a small project car. Note the word small …

What I ended up with is a car that would not fit into my garage until I had moved a large number of boxes that were neatly stacked. My wifes Tazz or my Banntam could fit in there no issues.

So what did I end up buying? A 1998 Ford Falcon XR6
Why did I buy it? Errmmm, by mistake actually. It’s really a funny story, and maybe one day I will laugh about it.

You see I have always liked these cars, they seem to be a cheap way to easy speed and power. So when I saw one standing amongst the 300 other cars I gave it a closer look. And when the time came for it to be auctioned off I stood closer as I had wanted to see how much it went for. The bidding stopped at R4 000 with the auctioneer calling R4 500 once..twice, at which point I looked at my wife and she said ‘buy it’, so I quickly pulled my registration card out my pocket and bid on the car.

Then no-one else did. So I had a car.

And all I had done was give the front of the car a quick once over, again I was not planning on buying a car, I only wanted to get an idea of the prices. Besides what better way is there to spend your day off watching other people buy fubar cars?? You can only get your car when the auction is done, so while we waited for the auction to end, my wife quizzed me on what was wrong with the car, was the back damaged, how was the interior, was anything missing? Sadly I could not answer her on anything so I began to get a little (VERY) despondent. Had I bought a dud that was destined for the scrapheap?

Thankfully when I got it home and sarted I could find no obvious reason for it to go straight to the heap, phew.

As I was busy preparing for exams I forced myself to stay out the garage so I could concentrate, so the car stood gathering dust. But only till the very day after writing my last exam.

Here she is! By the time I took the first picture I had changed the one wheel, which was so damaged I could not pump it up, and taken off the bonnet and the lefty hand side fender.
It looked better with them on but the bonne had been pushed back so I could not open it fully and the fender had also been pushed back, far enough that you could not open the passenger door.

Just a shot to show you how scrunched up the left hand side is, I am guessing the previos owner went off road and smacked a tree

Here you can see the damage to the front at the bottom of the radiator, naturally I did not see this on the auction day as I was not expecting to buy the car. Beginning to regret not taking a closer look before bidding now. Photo does not do the damage any justice though, it gets worse.

Closer view of the crumpled left hand side. Lots of work, lots and lots.

Pic may seem confusing but the engine is at the top left hand side of the pic, bottom right shows how deep in the damage goes, right up to the top of the shock absorber!

Here I made a cut (using a hacksaw) through the damaged front section where the light would be situated. I did this so that I could get the radiator out. It had been pushed way back and was up against the engine.

Still only one cut, but I bent the front section forward after taking the radiator out. I bent it to about where it should have been, starting to realise the damage is much worse than I had originally thought.

A view from the top, Sheesh, if you look at the engine you can see how close the front lower section is. Its almost touching the bash plate, while on the richt hand side I can easily fit my hand between the chassis and the engine

1 X radiator, stuffed. I wonder if this can be repaired? Going to have to make a trip to a radiator place and see. Also in the pic is the radiator for the aircon. It’s not that clear but that radiator is warped, I can probably bend it straight.

Stuffed cooling fans, If you look at the left you will see that there should be a rectangular section at the bottom left, what you cant see is that the housing for the fans is cracked all over, going to have to replace the whole thing I think.

Progress? I am not so sure, but here I have drilled all the spot welds and removed the whole front section. I am hoping to get better access to the engine as it’s going to come out. Without the front section there I dont need to lift the engine as high to clear the body, it can just come out the front!

Closer look showing how badly the the bottom section bent, if you look at the right hand side chassis rail (on the left in the pic) you can just see that it is bent. Oh dear, a fair bit of work will go into getting that right!

So am I mad? Should I sent it away, admit defeat? Naah. I prefer bumping my head again and again and again and ag…

Posted under Project Falcon

This post was written by Shaun on November 8, 2008

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