An Introduction: Chris Collins and Morris Tilly Project

[jack neville]

Time to finish the side panels.
First they need trimming to shape and folding the edges. I bought a couple of sheets of heavy plywood to use as a former. Placing an original panel to trace the shape I then drill a few holes into the plywood which are shared by both metal sides. The two sheets of plywood were bolted together through those holes and the shape cut out.

[jack neville]

One of the plywood sheets was laid inside the metal blank and the shape traced out with appropriate allowance for the folds. That shape was then cut out of the metal blank x 4 and then the two plywood sheets were bolted together with the metal sheet sandwiched in between.
A few clamps were added to secure the edges. I only need these formers to survive long enough to make four panels so they don't need to be too elaborate although I need 30 mm folded over for the wheel arch in a circular pattern which needs a lot of slow tapping and is a significant stretch..

[jack neville]

First panel done. Came out quite well.

[jack neville]

Two sets done. The formers barely suffered at all. Now just need a lot of holes drilled in them.

[jack neville]

With one set of rear side panels in place with their timber support and the roof all bolted up and in the correct position, I bolted a brace across the two B pillars to keep it all in place and then made up another new timber bulkhead which bolts to the rear of the roof.

[jack neville]

Using the other set of rear panels allowed me to lay out the timber frame as I cut each piece. A very time consuming excercise with each piece lapped into two others. I also did two sets at once so glad to have that out of the way.

[jack neville]

A bit more progress of the timber work. The side pieces are all now screwed and glued but not attached to the metal sides yet. The front main cross bearer is complete and joined up to the main pillar supports. The rear main cross bearer is cut to size and clamped in situ to hold the sides up. I am waiting on more timber for the rear tailgate hinge supports and rear floor step. I need that assembled to help get the whole body square before I put the floor boards in and make a tailgate. But before I can do that though I have to rebuild the inner wheel arches.