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Sam_Doman

Member since Nov 2008 • Last active Aug 2018

Most recent activity

  • in Miscellaneous and Meaningless
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    Some of you might remember a post from a few months ago, about a Subaru brat, which I pulled out of a hedge on a friend's farm. I've been working on it almost full-time since then, and it's finally all back together. Lots of welding, panel beating a fabricating, and have just taken it out of the shed, having resprayed it. Did everything myself, occasionally with a bit of help from friends. There are lots of photos from throughout the process, but can't download them from my camera at the moment, so here are a couple of very low res shots of the preview screen. Will post proper photos of finished product soon, and if there's interest; I could put together a gallery of the work.

    Edit: 'before' photos added for reference.

  • in Miscellaneous and Meaningless
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    Thanks. Been busy with work recently, so not as far along as I'd like by now, but the front end is coming together.
    This photo was yesterday, the front end is all made, dry fitted, and ready for glueing tomorrow. Grille with black wire mesh in the middle, and fog lights/ drl on the outside. Will update with photos soon.

    Edit: 'Before'photo added

  • in Current Projects
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    Soak it in Plus Gas (or whatever penetrating oil), then gently tap it. Try to avoid 'smacking it', unless all else fails.

  • in Miscellaneous and Meaningless
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    Been working on the brat this afternoon. Now all the structural stuff is done, so I tackled the front near-side wheel arch, which was the worst of the body work. Quite an enjoyable process: took a template off the other side of the car, to make the perpendicular lip, and tacked that in first, to hold everything in position while I made the repair pieces. Made cardboard templates, to cut out the sheet metal repair pieces, then hammered the compound curves into them until they matched the existing shape of the arches, then welded them in. Simple really. Happy with the results- the overall shape is good, and it all feels solid again. Obviously needs the welds polishing flush and a skim of filler before painting, but hopefully it should look about right...

  • in Current Projects
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    Just been putting this together. Used to ride a lot of trials, and always lusted after a mk1 justice, as the geometry is just so fun, and suits the style of riding I like to do. This one came up cheap, and in remarkable condition, with a reasonable spec, so I had to have it. Bought a new front wheel with a hope xc hub, to match the rear, so I can run a front disc. Also bought a wide-base surly single sprocket, to convert to ss. Stuck an old hope headset in too, and fitted some carbon renthal bars, that i had lying around. Also new tyres, hs33 pads and hoses etc. Needs some more work, including making a chain tensioner and a carbon fibre saddle, as the original plastic one was missing, unfortunately.

    (Excuse the shadow in the 'before' photo, it's from the guy I bought it from)

  • in Miscellaneous and Meaningless
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    Yeah, going to repair all the body work. A big part of the reason I took this project on is to improve my metal work skills, so it's all practise! I'm a boatbuilder by trade, so happy making templates for 3D sections/ compound curves. Just need to refine my welding a bit!
    Repaired the rotten door today, and pretty happy with how it turned out. Needs a little more hammering along the bottlm edge, but once it's had a light skim of filler and a coat of paint, it should look like new, hopefully!

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    Maybe a bit overkill, but i'd rather slightly overbuild it than go too light. The top rail (which took most of a day to design and make, and still need the ends trimming down) was added to replace the bolt-on, metal bumper, and the lower replace the mangled, old cross-member. This is all going to be covered by a fibreglass bumper.

    Edit: A bit more detail on the fabrication of the top horizontal rail: it started off as a bit of 60x40x2mm box, which I slit and re-welded to make the narrower bit, to allow for an extra, lower grille. As careful as i was, the heat from this welding distorted the section, putting a fairly uniform bend in it. To fix This, I had to make perpendicular slits along the bent section, and re-weld them, whilst the whole thing was clamped to a stiff section of heavy steel pipe. It was a lot more work than it needed to be, but happy with the finished result. Nice and straight now. Then used the same technique to taper the ends in to the same angle as the headlight surrounds. Because the box is stiffer in this plane, it didn't bend s noticeable amount .
    Anyone with some welding experience know how I could have avoided the bend?

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    Bit of brat progress: before/after of the front end.
    Finally managed to source both replacement windows, and have a new windscreen seal on the way from Australia.
    All the chassis and structural work is basically done now, ready to start sorting out the body work- the fun bit!

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