Preparing For Dallara Body Kit

Discussion in 'Workshop Forum' started by lookforjoe, Mar 7, 2015.

  1. lookforjoe

    lookforjoe True Classic

    Mostly small stuff again today. Stripped the windshield trim again, filled, primed, sanded & painted them. Not perfect, but good enough.

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    Trimmed the trunk lid spoiler undersides where they come close to the fender.

    Install frunk seal.

    Problems with the paint on the DS mirror also. Futzed with that for some time, sanding, cleaning, repainting.

    Applied base to the inside of the engine cover, and the trunk lid inner.

    Clear coated the engine cover & the trunk lid inner. Reinstalled trunk lid, seal & adjust.

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    Clear coated door handles & mirrors.

    Test fit the PS door handle. Not feeling the chrome lock cylinder. Didn't want to paint the entire thing red.

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    blacked out the cylinder

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    Finished up the window frames

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    Finished painting the misc trim pieces

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    Hopefully tomorrow I'll get the rest of the body sanded and mayber start putting the trim back on.
     
    dllubin likes this.
  2. Huey

    Huey True Classic

    Location:
    Xenia, Ohio
    Looking very good!
     
  3. sub-zeroil

    sub-zeroil True Classic

    Location:
    hollywood fl
    looking good sir
     
  4. lookforjoe

    lookforjoe True Classic

    Put the car in the street yesterday.
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    More small steps today.

    Sanded & cut, polished the windshield frame & cowl. Installed the A pillar trim and the Targa seal. Windsheild trim will be glued next.

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    Installed the Fixed Glass / window channels.

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    Wet sanded & cut the PS fender, door, sill & upper nose panel. Installed the PS rocker trim & xpel film on the sill. Need to use cutting & fine polishes next.

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    Installed the taillamps. Still need to wet sand & cut the entire rear panel

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    Last edited: Aug 23, 2018
    Anandastar, 81x, autox19 and 2 others like this.
  5. Huey

    Huey True Classic

    Location:
    Xenia, Ohio
    Jealous
     
  6. kmead

    kmead Over half way.

    Location:
    Michigan
    I bet that stopped traffic.
     
  7. autox19

    autox19 True Classic

    Location:
    East Lansing, Mi
    Beautiful!!!!
     
  8. lookforjoe

    lookforjoe True Classic

    Thanks guys.

    Getting close now. Cut & polished the DS door. Installed the door handles, locks & catches. Polished the nose upper, the PS fender & PS door.

    Repainted the outer door trims & cleaned the glass seal strips. Added small sections where there were gaps on both sides.

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    Installed the windshield trim with 3M VHB 4991 (1/2", 1.9mm thick) adhesive tape
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    Painted the brushed aluminum "Bertone" sail tags black, with red "b" accent.

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    Tomorrow I need to get the headlamps and markers back in, and reassemble the doors. Also need to cut & polish the rear panel & PS 1/4 still.
     
    Yves likes this.
  9. puntobarney

    puntobarney New Member

    Location:
    dungloe irland
     
  10. kmead

    kmead Over half way.

    Location:
    Michigan
    Remember that VHB is a PSA so it needs around 20 psi force to get it to properly wet out. The thick tape (1.9mm) you used should do a good job of conforming to irregularities.

    Use a wallpaper roller or similar roller to apply pressure.
     
  11. lookforjoe

    lookforjoe True Classic

    Wasted about 3 hours ( I did get to completely organize all my M6 and smaller machine and screw hardware though :D ) this morning trying to find the correct screws for the door seal - targa seal elbow. I bought the early style elbows from MWB a couple years ago, and the center strip recently, so I figured it would be a good time to put them on. Ended up going to HD for #4 stainless screws. These elbows required drilling new holes, the later elbows were secured further inboard.

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    After that, I cut a Volvo V70 door seal for the pass door, put the sill plates back in.

    After that, I put seam sealer on the inner nose seams and then started on sanding & polishing the spoiler & lower nose section.

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    That done, I put the grille, the headlamp housings, horns, and markers back in.

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    Still have to cut & polish the rear and PS 1/4. After that, I need to put the engine cover back together & polish that.

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    Pressed it in place by degree, pulling the release tape as I went around. The main issue is that the lower corners don't sit down on the glass evenly. I had to work hard to get those down.
     
    Last edited: Aug 25, 2018
    Rodger, JimD and dllubin like this.
  12. kmead

    kmead Over half way.

    Location:
    Michigan
    A little heat to get things to conform, rolled and some regular tape to keep it down can do the trick.

    Things are looking great. Most envious from over here.

    It is great that you are finishing this up in time for the fall driving season which is my favorite time. Enjoy your weekend.
     
    lookforjoe likes this.
  13. Huey

    Huey True Classic

    Location:
    Xenia, Ohio
    Love those wheels!
     
  14. lookforjoe

    lookforjoe True Classic

    Finally done with main panels cut & polish (for the time being) - there are areas that could use going over again, but that will have to wait. Still have to do the trunk, the hood & the engine cover. Had to futz with the trunk to get it to latch with the new seal. Frunk has a similar issue where it sits a little high with the new seal.

    Back end

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    front end

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    rjplenter and dcioccarelli like this.
  15. lookforjoe

    lookforjoe True Classic

    Worked on the doors/windows/regulators the past couple days. Added reinforcement in the area beween the armrest retaining screw mounds.

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    Bonded those in place today, then sanded and polished the targa top panel and cleaned, installed and adjusted the targa retaining plates.

    After that, I worked on the engine cover. Drilled out the rivet holes to accept M5 riv-nuts. This way, I can disassemble for cleaning as needed.

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    Wet sanded & polished the outer cover

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    painted the rain tray with cheaper black lacquer & clear coat (Duplicolor)

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    Last edited: Oct 23, 2018
    aarpcard and dllubin like this.
  16. lookforjoe

    lookforjoe True Classic

    Put the engine cover together today. Heat & humidity were brutal today.

    Screen
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    rain tray back in, cover installed

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    After that, I cleaned the sail trim plastic backing, and painted the metal trim

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    altogether now. Ready for School in the AM :D

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    painted the door fabric flat black also

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    Rodger, mkmini and kmead like this.
  17. kmead

    kmead Over half way.

    Location:
    Michigan
    Great first day of school pictures.

    We had our last first day with our daughter a week and a bit ago (her brothers both graduated several years ago).

    Looks like a fun time. Enjoy and good luck in the parking lot...
     
  18. Huey

    Huey True Classic

    Location:
    Xenia, Ohio
    I can't get over how beautiful that came out. You should be exceptionally proud!
     
    lookforjoe and kmead like this.
  19. RZSR X

    RZSR X True Classic

    The body lines came out very nicely, all the work really paid off! I like the "911" sucker fan idea although I wonder how much of a difference leaving the top slats in would have made with the air flow. What are the black rubber? dots on the sills for? And what grade sandpaper did you wet sand the paint and or clear with? It looks smooth!

    Now what are you going to do with the rest of your life?
     
  20. lookforjoe

    lookforjoe True Classic

    Thank you.

    Removing the slats did make a difference - you can feel the volume increase, I did leave them originally.

    The black dots are the plastic retainer rivets for the modified Volvo rocker extensions. They are also glued to the sill along a 1/2” strip with 3M VHB tape, and plastic rivets along the underside.

    I (block) wet sanded using 1k, 2K, 3K, 5K & 7K before using the DA with 4 levels of compound thru fine polish. It is very smooth :) .They said no wax for at least 3 months.

    Next up is custom dash, and K24 conversion, so that will keep me busy for the next couple years....
     
    sub-zeroil likes this.

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