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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Pymmie
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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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Mk3 Int 128/4451 - SW Area Rep (Devon/Cornwall)

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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Pymmie
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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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Mk3 Int 128/4451 - SW Area Rep (Devon/Cornwall)

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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johnw
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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.
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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 !!!!
toonkojak
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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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