Interceptor bodyshell/chassis built from scratch

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Chris_R
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Re: Interceptor bodyshell/chassis built from scratch

Post by Chris_R »

The variation of tailgate fitting has always been a topic that has puzzled me. I would have thought that the glass largely dictates the width and shape of the tailgate and unless there is significant variation in glass size then the opening where the glass sits of each tailgate must be very closely matched on each and every tailgate. To get that kind of accuracy for the shape of the glass implies a degree of accuracy of all tailgates otherwise glasses simply would not fit.
The rear of the car is made in a massive jig which I would have thought should also have ensured a high degree of consistency. An article published in "Welding and Metal Fabrication, June 1968" shows the jigs and describes the methods. These pictures are from the article.
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The first picture shows the complete rear end being made as a sub-assembly. This is obviously made separate from the tailgate as there is no roof section or tailgate mounting section present.
The second picture shows the jig where the front end, rear end and roof are added, in that order, each having been constructed as sub-assemblies. The article describes its use thus: Hinged frames are used to locate the apertures. The door apertures and rear quarter light apertures are located by such frames. Similar frames are used for the rear window and boot apertures. In each instance, the hinged frame is locked against positive stops and acts as a checking fixture for ensuring alignment and position of the panels. When the welding is completed in this jig little else is left to complete the body assembly and the loading trolley is taken out and rolled onto the transfer trolley and a number of final welds are made to complete the attachment of sills, outer wheel arches and windscreen flanges.
This is shown in the third picture before it is passed to the body finishers for the final operations including lead loading, bonnet fitting, door hanging and so on.
The article concludes with the words "In a car of this class these items are of considerable importance and much of the care taken in the welding work is repaid by the minimum work necessary at this stage".
Chris
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Re: Interceptor bodyshell/chassis built from scratch

Post by sticky »

Grant wrote:He did offer to deliver it for that money Stephen too, but, Although I know it is a lot of work to make I felt it was un-affordable for me, I wouldn't have any problem driving there though and I had already thought of that too. Love a road trip in a Transit :P
Grant not like you to move that far from originality steel sun roof noooooo
sticky by name stick at it by nature !!!!
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Re: Interceptor bodyshell/chassis built from scratch

Post by Pymmie »

Updated pictures from Jacek.

Looking a much better fit.

John P
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Previous Jensen Owner 2010-2022 (128/4451)

Understeer - Hitting the fence with the front of the car
Oversteer - Hitting the fence with the rear of the car
Horsepower -How fast you hit the fence
Torque - How far you take the fence with you
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Re: Interceptor bodyshell/chassis built from scratch

Post by Pymmie »

More updates from Jacek.

I believe he has finished building a body shell from scratch.

Wow

John P
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Previous Jensen Owner 2010-2022 (128/4451)

Understeer - Hitting the fence with the front of the car
Oversteer - Hitting the fence with the rear of the car
Horsepower -How fast you hit the fence
Torque - How far you take the fence with you
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ajc9415
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Re: Interceptor bodyshell/chassis built from scratch

Post by ajc9415 »

What a fantastic achievement!
Adrian
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Re: Interceptor bodyshell/chassis built from scratch

Post by johnw »

All in under 1 year, including making tooling and jigs, while continuing other projects for customers. Interesting tool made for making bonnet skins in one piece.
Have you seen our stolen Jensen FF 119/011 https://twitter.com/jensenffdotcom
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Re: Interceptor bodyshell/chassis built from scratch

Post by sticky »

Pymmie wrote:Updated pictures from Jacek.

Looking a much better fit.

John P
on my car the stainless rear door frame has a section of steel around it's about 30mm wide
sticky by name stick at it by nature !!!!
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Re: Interceptor bodyshell/chassis built from scratch

Post by toonkojak »

johnw wrote:All in under 1 year, including making tooling and jigs, while continuing other projects for customers. Interesting tool made for making bonnet skins in one piece.
I met Jacek a few weeks ago. I visited his place, not far from where I live, and we had a good 3-hour-or-so chat. He seems a very talented panel beater. He works alone. He has some impressive tooling in his shop and knows how to use it.

In fact this project took him 2000 hrs - that's what he told me - and he was 100% focused on this build, doing no other projects in the meantime.

He mentioned his next one would be a Capri. I also saw in his shop a Granada Mk 1 Estate in need of some bodywork. He seems to be a Ford afficionado.
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Re: Interceptor bodyshell/chassis built from scratch

Post by Zapek »

Hello gentelmans.
I’m the one who made this creation. Thank you Jonathan for share this archivement and you all for coments.
That was not easy to build that bodyshell from scratch but I made a lot of tooling and some jigs so the next one will be easier.
The next one. That’s right.
Some time ago I heard about one poor FF in Hungary so start to looking for more information.
I found them in Budapest in DC72 workshop.
Next I found the owner and here it is.
FF 119/034 is in my hands in Poland now and is in need of new bodyshell. Yes.
If you are wonder of next bodyshell recreation in my workshop please give me a sign so I share an archivement as do it Jonathan.
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ajc9415
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Re: Interceptor bodyshell/chassis built from scratch

Post by ajc9415 »

Zapec, what you have achieved is fantastic. Please post pictures of your work as it progresses.
Adrian
1974 Interceptor Mk III 2240-9415
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VFK44
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Re: Interceptor bodyshell/chassis built from scratch

Post by VFK44 »

Any pictures of how it looks now?

Did you restore all of it, or just provide the new bodyshell?

We look forward to the next project.
"Now that chassis number is particularly interesting ‘cos it’s the one after the one before, which is the one after mine, not many people know that"
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Grant
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Re: Interceptor bodyshell/chassis built from scratch

Post by Grant »

JacekImage..We spoke once about a roof panel for me and being delivered to the UK? do you remember that?..Anyway..Jacek..your are so "Rich"....In clevernessImageImage..I admire your skills and cleverness very much indeedImage..
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Zapek
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Re: Interceptor bodyshell/chassis built from scratch

Post by Zapek »

Interceptor is still waiting for paint job. My job was to fabricate a bodyshell only. The rest of renovation process make different workshop. I’m happy to finished my job because there was a Covid pandemy while so the owner lost a financial stability. Now it’s a war behind a east border and still it is not good time for finish this car.
FF 034 it’s mine car so there should be no reason to stop works for so long time.
Grant, I don’t remember a details but I talked with fev persons about a roof.
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Re: Interceptor bodyshell/chassis built from scratch

Post by Series3Jensen »

Zapek

You are a very talented person

I note that you own 119/034
I have some early history on this car
Originally Mist Grey with a Red interior
UK Registration Number TPJ 1 F
Previously owned by Royalty ??
Dry Stored from 1992 to 2002
For Sale in JOC Magazine 164 07/08.2002 by JOC Member Dan McGlade - Membership Number 5569
A previous owner of this car also owned Chassis Number 119/002i

Another challenge with the FF bodywork being circa 4" longer

I applaud your work

Kind regards

Jim Smith
Mem No 1639
136/8791 RJF 17 owned since September 1978
Zapek
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Re: Interceptor bodyshell/chassis built from scratch

Post by Zapek »

I know Chris McGlade, he is a son of Dan. Chris gave me a sign about FF in Hungary. That was the begining of my adventure with this 119/034.
I heard about his history a lot, that is amazing car with lot of nice rare details. It is almost 100% complete.
I’m gonna show you this car as I bought it with all interesting things that I found.
I am in contact with John Wild who ask me a lot of questions about a car and so we explore togerher them. It is amazing and I’m determinated to make a restoration on high level but with maximum original parts. Unfortunatly body shell is critical bad so propably I made them all new.
My idea is to this new creation of 119/034 will be for sure in complete with old original body shell.
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