D72 British Bellytank

[BikerGran]

I'm in awe!

[TerryFwit]

Thank you, right had enough of flaps at the moment so had a go at flange instead.
No really, started on the exhaust flanges. Cut some strips of thin steel about an inch wide and fold down their length in half making lengths of angle. Found an offcut of tube about 62mm as a guide and start stretching.

D72 British Bellytank

D72 British Bellytank

And one ready made flange kit. Bent up more than needed and cut the straight bits to 18". You can see the offcut used as a guide top right of pic.

D72 British Bellytank

Enlarged the slots to about 65mm and rounded out the ends.

D72 British Bellytank

Test fitted the best of the end pieces.

D72 British Bellytank

Fitted the top and bottom sections first in the same way as the air vents 5mm dome head allen bolts

D72 British Bellytank

Then trimmed up the end pieces to match, just need to tack together before removing and final welding.

D72 British Bellytank

Exhaust refitted.

D72 British Bellytank

[Manky Monkey]

That really is a wondrous tool isn't it -oh, how many times have I heard that over the years ...well, not that many actually.
Could've really used that on a few builds. The details are really putting this project one notch higher than most -there's been a steel belly tank racer -well, aluminium I guess, at the Dutch hotrod show I go to for the last couple of years. Very nice, but not finished to anywhere near the standard of your 'glass one.

[TerryFwit]

Thanks for the positive comments, problem with building something is you know all the little flaws which always draw your eye preventing you from seeing the whole product. Or is that just me ?
Anyways going to cut the body again next.

Kev.

[Manky Monkey]

Yup. Joe Public just see a nice car, or bike, or bellytank. If you've built it you know every ripple in the bodywork, every flaw in the paint etc.

[TerryFwit]

After the fuel flap disaster we still needed another one this time at the front. This is so we can access the brake fluid reservoir and the fuse box, was never keen on this as in 5 years of racing the trabant we have at the track changed one fuse and topped up the fluid once. The others insisted it was accessible so, after many hours of just staring at it I decide to make whole front removable and using the minimum amount of cuts required.
Marked out the cuts with masking tape, carrying on the engine cover cut all the way down to the lip.

D72 British Bellytank

D72 British Bellytank

And two cuts behind the roll hoop.

D72 British Bellytank

Meaning this whole section from the tape forwards will be removable.

D72 British Bellytank

 

[TerryFwit]

Removed the firewall flange.

D72 British Bellytank

And cut down to the lip.

D72 British Bellytank

Did the same on the other side and then took front off before cutting away the top piece.

D72 British Bellytank

D72 British Bellytank

[TerryFwit]

Ending up with this.

D72 British Bellytank

Or this

D72 British Bellytank

Or this

D72 British Bellytank

And together

D72 British Bellytank

And as a little treat I put it all back together and ended up with this.

D72 British Bellytank

Rather pleased....still don't like the fuel flap.

 

[Manky Monkey]

For a minute there I thought you were going backwards & making a huge change that might not work out -but I shouldn't have doubted you -very sensible to have the front removable & everything still seems to line up perfectly when it goes back on. In the event of a crash/fire/change of underpants etc, some quick release Dzus fasteners would mean quick access to the cockpit area -makes perfect sense.

[TerryFwit]

Front section will still be bolted together, in total 35 bolts. Will only take 5 -10 mins to remove. The others wanted 'serviceable' well I gave them 'accessible' 
On with the front section, marked up with masking tape the shape of the opening around the spring and shock.

D72 British Bellytank

Cut away and checked for clearance.

D72 British Bellytank

Then made a template for other side.

D72 British Bellytank

D72 British Bellytank

And then marked up the other side.

D72 British Bellytank

Cut that piece out and hoped they matched.

D72 British Bellytank

And checked back on the car, so far so good. Next more flanges.

D72 British Bellytank

[TerryFwit]

Made flanges in the same way as all the others, Little bits all shrunk and stretched to the right shape before being welded together which is not done yet as that is one thing I cannot do. No point trying as the others can all weld so leave it to the experts.

D72 British Bellytank

D72 British Bellytank

D72 British Bellytank

D72 British Bellytank

A quick check before fixing and trimming.

D72 British Bellytank

And one side done.

D72 British Bellytank

Made the same for the other side.

D72 British Bellytank

Checked to see if this one fits.

D72 British Bellytank

And done, and they look quite equal and in line so happy with that. Next up rear axle openings and yep, more flanges.

D72 British Bellytank

[Manky Monkey]

I do like that shrinky doofer.
What are your lever arm shocks from? Sherpa, (I cut a Sherpa van up a few years ago but can't remember what dampers it had). My Pop uses the rear lever arms from a Moggy Minor, but if I'm driving on my own, the body settles to the driver's side. I wonder if stiffer dampers would help.

[TerryFwit]

I think they came off an old ford Pop from memory and the spring is from a morris 8. Basically using what ever is tucked away in our garages.

[minimutly]

I do like that shrinky doofer.
What are your lever arm shocks from? Sherpa, (I cut a Sherpa van up a few years ago but can't remember what dampers it had). My Pop uses the rear lever arms from a Moggy Minor, but if I'm driving on my own, the body settles to the driver's side. I wonder if stiffer dampers would help.

No Andy, shock absorbers, or dampers are just that. Springs hold you up. Fit stiffer springs, move them out, or fit an antirollbar. Maybe all 3?

[Manky Monkey]

I've got a transverse leaf on the front, the same as Terry's bellytank, so can't do any of those.