|
To set the total width of the roof and upper side panels I followed the book and measured the length across the top edge of the windscreen. I temporarily assembled the roof, upper side panels and screen side pillars and transferred this dimension to the assembly. I figured it was wise to maintain maximum screen dimensions with the minimum of trimming but I was left with a gap of around 1 inch each side between the roof panel vertical returns and the side panel vertical returns. Bonding the three upper panels together seemed the way to go. I Cleko’d the panels and offered-up the screen. It was a near perfect fit - I didn’t have to trim the top screen edge at all. I drilled and Cleko’d the top of the screen, supporting the bottom edge in roughly the right place. The forward dog-house didn't sit at all well on the returns so I decided to join the three panels into one.
 |
I cut off the vertical roof returns completely and made saw cuts a one inch intervals along the rear angled roof return (where it fixes to the seat back). I still had a slight crease forming at an angle across the front of the side panels so I made two angled saw cuts, removed a 1/16 inch slice of material and bonded the cut back together from below.
With my trusty Panel Saw I made cuts approximately 8 inches along the side panel vertical returns so that they would better form themselves to the shape of the dog house,
I laid up 3 inch strips of GRP a stage at a time on the underside of the panels. Upside-down laminating ain’t easy - just do it a small piece at a time. When you have enough strength in the joins you can remove the assembly and continue to work on the bench but be sure to support the panels in their intended shape.
I sat the forward dog house panel in position and re-glassed the fixing flanges from below, then bonded across the gaps, above and below to form a single panel.
Again, using packing tape on the seat back as mould release, I reinforced and extended the rear roof return with new GRP
Here’s the final rear edge with nut plates fitted and fully blended - in with the sides. In the centre is the cut-out for the switch panel.
And here it is painted.
|
