Time lapse full metal Broadspeed GT restoration/transformation

[turbocox]

I think his one is due to be in paint soon...(I think)...

[Dr.Mabo]

Are you making a contest with Paul Wiginton?

Oh, I would never even think about a contest with Paul . He is an educated and professional bodyworker with ages of experience based on Aston Martin.

I'm just an enthusiast who only passed a two weeks panelbeating training.

I think that would be a rather unequal competition

But I'm honored you even consider it

[Dr.Mabo]

The new roof shape also needs new inner cant rails. I was able to reuse about ¾ of the original cant rails. The area between A- and B-pillar didn’t need any modifications. But from the B-piller rearwards I had to reshape the profile. First I reduced the inner upper radius of the quarter light frame to match the modified radius on the outer side. With some stretching and bending I was able to bring the rear end into the smooth radius of the quarter light. Thus I only had to build the last quarter with its sharp radius new. I cut out a wooden buck and hammered the panel around it. First the outer side, followed by the inner side.

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[Fanfaniracing]

Nice work as always and very good technique

[Dr.Mabo]

Thanks Fabian

Here are some pics of the modified upper radius of the quarter light frame.

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After this was welded back on the inner cant rail I continued with the newly formed end part.

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This is the finished cant rail ready to go back under the roof.

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[Dr.Mabo]

Next was the connection between the side cant rail above the doors and the cant rail above the windshield. The original is a separate corner piece, which can be seen in the first picture on top. The difficulty is that the chopped roof not only makes the connection go around the corner, but also has to compensate the height difference. I first tried to modify the original piece so that it fits into the new shape. But that did not work at all. So I had to build it from scratch. But I lacked any imagination how to bring this three-dimensional profile into the desired shape . So I had no other choice than to just start somehow .

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I then built it in two parts, which I welded together in the middle.

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After grinding the weld seam I was quite satisfied with the finish and the fit . But that was just half the way to go . Now I had to build the same part again mirror-inverted.

[mk1]

Thanks for the latest update Doc!

I was starting to get withdrawal symptoms.

That is one fiddly looking cant rail.

You said "I lacked any imagination how to bring this three-dimensional profile into the desired shape" I would suggest that the evidence in your photos says otherwise

[Dr.Mabo]

To be honest, the photos are already from the second corner piece. On the first one I just tried around and cursed a lot , but didn't take any photos

[mk1]

Now that is what I call a good plan

[Nick W]

I remember having a nightmare with those on my standard shape shell I built..
What you are making is amazing

[Pandora]

Every wee bit of this impresses me, but added up, it's incredible!

Al

[Dr.Mabo]

It is helpful to prepare and also weld large and complex parts as far as possible outside of the vehicle, and then connect them to the body as a complete assy. This is how I did it with the parcel shelf and the inner frame of the rear window. Of course, I lined up both parts in the body shell, but then welded them together when they were removed. This makes life a lot easier.

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The same goes for the side roof cant rails including the corner pieces.

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Finally, I welded all three segments in the Mini to the body, the roof and to each other.

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[Charlynsane]

Wonderful work as usual! the project is near complete now!

Just for information , what is that yellow paint ? antirust?

[mk1]

I have seen a few original GT's & have seen others made of steel before, but yours s by far the best I have ever seen!

I'm looking forward to the next instalment already.

[UHR850]

Oh so nice to follow and enjoy your craftsmanship.

Kees.

[Dr.Mabo]

@ Charlynsane
The yellow paint is anti corrosion Etch Primer from PPG.

@ Mark
Thanks for your credit. I'll keep that in mind for now, because the Broadspeed is far from finished and things can still go wrong

But now It’s again time for an update. Now that the roof including all stiffeners were ready, the decisive moment came - installation of the rear screen. The question was not whether it would fit in the cutout, but whether the flow would match the roofline. That was one of the few things I couldn't calculate or try out in advance. The trailing edge of the roof panel is quite wobbly without stiffeners and can easily be welded a few inches higher or lower to the stiffener frame. But, I'm a lucky boy. The flow along the roof continues cleanly in a sweep from the rear screen. If there were a kink in the transition, the overall picture would be massively disturbed.

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And because it's so pleasing to the eye, the taillights and lettering are also mounted for test purposes.

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After some extensive watching sessions, I continued with the sheet metal work. On the early Minis, the fresh air supply for the heater is achieved with a long hose through the engine bay. And that always gets in the way. On later Minis, the fresh air supply was implemented through the wheel well. Actually clever, if not right before the front mask the supply is still diverted into the engine bay, to then collect the air behind the grille. The plastic knee also takes up a massive amount of space. So I shifted the air intake for the Broadspeed, as I did in my earlier restorations, completely into the wheel well. To do this, I first had to build the side exit into the wheel well.

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[JC T ONE]

Very nice project - just finished off all 24 pages.

Keep up the good work.


Jens Christian

[Clubman gt]

Is the rear window custom made

[roger mcnab]

hi doc
the air intake is in the same spot on my clubman i was thinking of collecting the air about where the right indicator is situated under the bumper as
there is no room in the engine bay with the rover v8 in place and the massive bell housing for the 1800 gearbox
this project is coming together very well it is a credit to your patience and skill it will be stunning with the right color
have a great christmas and happy hammering
cheers roger mcnab

[mk1]

Another excellent idea moving the air intake. I have always thought that was a much better solution than the standard MK1 ever had.

More grwat work.

I hope you bring in to Blyton when you are all done.