Time lapse full metal Broadspeed GT restoration/transformation

[Dr.Mabo]

Eventually I received all the panels I ordered. Before I could even think about the Broadspeed transformation, the shell must be solid. All the typical corrosion damage should be removed. And that’s what I had to do first. The m-machine inner/outer sill to first flute is a fantastic panel when you don’t need to change the full floor. I can handle it by my own and I don’t need a body jig. It just has a very long seam. In my last project I used the same repair section and MAG welded it. It took hours of grinding and I’m not happy with the structure change of the metal due to MAG. It makes the seam very hard, that’s why you see many welding repairs, which cracks after a short time, right beside the welding seam. It doesn’t happen to my previous project yet, but might happen one day.
Since I plan the Broadspeed project I became a fan of gas welding. The seam will have the same structure as the material around it, thus it is flexible and you can shape the weld without cracking. If you do an excellent preparation, which is the key of success for all welding technics, you can just weld both parts together without additional welding rod. Of course there is some planishing necessary during tecking and final welding, but very very little grinding. Your neighbors will love it.

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So I did the main seam of the inner / outer sill to the floor panel with gas welding. The connection to the doorstep with a spot welder.

As you can see on the photos no grinding on the seam. I’m pretty happy with the result.

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so long
the Doc

[Dr.Mabo]

One of the most sophisticated jobs is to build the tail panel. The shape and the symmetry is extremely important. But no measures no pattern or bucks are available. If you have nothing, you have to start somewhere. And this was with a flat piece of sheet metal. Slowly I formed the edges and started to form the recess of the left taillight.

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so long
the Doc

[seandoyle]

Fascinating .Keep them coming !!

[roger mcnab]

hi when i started thinking of doing the unipower gt replica i thought about how to do it no plans available so t worked out that with good straight on pics i could work out the shape of the body and it scales out very well but not if the pics are at an angle luckily there hundreds of pics to use on the net so the shape is coming along well i need to get back on to it as i think i have got all the bits that are nearly all gone even got the windscreen frame very hard to source rear wind screen is not available at all so a comprise is needed
happy shaping roger mc nab

[Dr.Mabo]

@Roger,
are you doing the Unipower in metal or glasfiber?
Good luck and keep on building.

[Dr.Mabo]

The recess is made of two sections. The cutout in the panel with the smooth edges and the cover. This comes on top of the cutout with the seam on the sides. This makes flattening the seam easier and makes it invisible at the end.
The NOS tail light fits nicely.

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so long
The Doc

[roger mcnab]

hi doc
it will be fibre glass as that will be easier than metal and have the steel frame it will also have rover 3.5 v8 with austin 1800 gear box
the mgbgt rear window is the right shape so that will do but this is a long way off yet
cheers roger mcnab

[mk1]

This is brilliant!

[GTM71]

Are they Hillman Minx rear lights?
I like them, I'm using them on my GTM, lovely work by the way, interesting thread!

[surfblue63]

Are they Hillman Minx rear lights?
I like them, I'm using them on my GTM, lovely work by the way, interesting thread!

They are Lucas L572 lamps. Used on many Rootes Group vehicles, including the Sunbeam Rapier, Commer Cob and Singer Gazelle

[ferret]

Really enjoying this build

[Dr.Mabo]

Of course the back panel looks better with two taillights. So I did the same task on the other side again. Next was the space for the number plate. These was just cut out, bend backwards and closed with a matching filler panel. Again all gas welded.

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so long
The Doc

[UHR850]

O whow, you are a... I do not know how you call that in English.

[Old English White]

"Talented metalworker"?

[UHR850]

If you say so, yes you are.

Kees

[Dr.Mabo]

"Talented metalworker"?

Thanks for the compliments

In fact, I wouldn't discribe myself as talented. I would rather say, I'm very structured. I just follow the philosophy: If you can't handel the whole elephant at once, cut him in slices. And that's what I do with the Broadspeed. As long as I look at the whole car, I would never say I can build that. But focusing on one edge or just a tiny part, I say, yes I can do that. And at the end, I just have to put all the tiny parts together. And I'm pretty sure all of you do it that way when you start with a complete Mini restoration.

so long
the Doc

[Dr.Mabo]

Now its time for the corners. The upper corners are a lot more challenging then all the other parts before. The reason is they have a so called “reverse curve”. The two radiuses go into opposite direction. To form something hollow or domed is not that difficult. You just stretch the metal into one direction by hammer or machine until it matches with the desired pattern. With a reverse curve, forming one radius usually eliminates the other radius. Thus you have to form both radiuses at the same time. It took me a lot of head scratching and rejects to come to the final result. Funnily, I was working on the left edge and eventually it fits on the right.

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so long
The Doc

[roger mcnab]

hi doc i am not very up on the broad speed shape but it looks interesting but as you said to eat an elephant just take one bite at a time job done so you are making some head way just like my mini v8 clubman and unipower gt one step at a time and cut off the mistakes and start over
keep up the good work and all will come good
cheers roger mcnab

[Hipwell]

Great work so far! Look forward to seeing you progress.

[Dr.Mabo]

After all four corners are done, its time to cut the outer edge down to the correct length and flare the top and side edges.

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After about 100 hours the rear panel is ready. I’m quite pleased with the result. If you miss the exposed tail bumper section, I skipped it. This is the only external modification I decided to do. In my opinion a bumper should have the chance to move a bit and to be exchanged/repaired without any major bodywork, to do its bumper job properly. This is difficult as long as its part of the body structure. I will use the Elf or Hornet chrome bumpers as installed on the British Broadspeed, currently located in New Zealand.

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The registration plate is just selected randomly to fill the space. It has nothing to do with the car.

so long
The Doc