Malibu to Aston Martin conversion

Show off your work! Anything from final results to full start-to-finish project journals.



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PostPosted: Sat Mar 04, 2017 8:54 am
Finished the outer skin, ground, filled and primered. Built extensions to the inner door jam to fit the new shape, and supports for the lower quarter.
Attachments
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PostPosted: Sat Mar 04, 2017 9:08 am
Also had to build the door extension. Then off to the other side. Using paper templates to repeat the shapes on the other side, about every 3 inches , as the shape changes quickly. I also made long angled pieces of sheet metal, and used the shrinker stretcher to make templates of the front-back shape, to duplicate it on the passenger side.
He wanted an external gas filler, just like on the Aston racers, so I had to buy a quick opening door, and make an adapter to go to the fuel filler.
Attachments
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Joined: Tue Sep 16, 2008 1:17 pm
Location: Pahrump NV.
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PostPosted: Mon Mar 06, 2017 10:03 am
WOW! I am Blown away! :shocked:

Very Cool work love to see MORE! :worthy:

I would love to attend on of Wray Schelin Coach building classes some day.
Mean while I will keep watching and listening to guys like you and pick up what I can.
Dennis B.
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Tue Mar 07, 2017 6:12 am
Also had to make extensions to the rocker panel, to match the width of the new quarters and doors.
The front end was a bit easier. The owner bought new Aston fenders, bumper, and grill. The width was a pretty close match, and the fenders are made of a hard plastic resin, that fiberglass boded to easily. The first step was to center the fender around the front wheel. I had to cut about 8 in. off the rear edge of the fenders to fit.
Attachments
Astom_M_9.jpg
Astom_M_9.jpg (17.64 KiB) Viewed 5563 times
Aston_nose_1.jpg
Aston_nose_2.jpg



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PostPosted: Tue Mar 07, 2017 6:16 am
The fenders had a MUCH lower profile than the stockers, so I had to cut down the top of the radiator support to be able to fit them and the hood. Even this had more work, as I wound up having to cut in a relief to clear the AC hose. I used a piece of exhaust pipe to fill in the relief cut. Had to fabricate brackets for every factory mounting hole, as well as bumper support pieces.
Attachments
Aston_nose_3.jpg
Aston_nose_4.jpg
Aston_nose_5.jpg
Aston_nose_6.jpg
Aston_nose_7.jpg



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PostPosted: Wed Mar 08, 2017 11:49 am
Chop
Do you have any links to other work you have done?
Dennis B.
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Thu Mar 09, 2017 5:48 am
Dennis, I have a website, but it's not current, and I have some trouble with entering new stuff on it, though it does have a lot of my old work. Customsbyflash.com. I keep updated on Facebook, same name, and there are albums there, as well, though not as complete with the older builds. Mostly old cars, customs, and rods, though there are quite a few muscle car builds, as well.
Thanks for the interest!



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PostPosted: Thu Mar 09, 2017 6:05 am
Once the fenders were in position, I started on the hood, knowing it would take a long time. I have never worked with aluminum before, so I was both excited, and worried!
I started by building a tubing framework for it, in steel. The edges would have "L" shaped pieces welded to the tubing, so the aluminum skin could be folded over it, to attach it. So the L pieces had to have the right gap, and perfect contour to match the fender edges.
Attachment points for the hood hinges, and latch had to incorporated into the stonger steel frame, too.
Again, cardboard pattern, cut out the aluminum, mark off the body line I wanted, and used my bead roller (with 'tipping' dies) to make the bend, as it was curved. Then the edge was trimmed, so I could use my shrinker to put in the right curvature of the center panel.
Attachments
Aston_Malhood_1.jpg
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PostPosted: Thu Mar 09, 2017 8:05 pm
Chop
Thanks I will check it out.

On Your project there you do know that Steel and Aluminum touching is a no no right?
It will cause Galvanic corrosion, Just the two metals touching Bare causes it. Its slow and would take some time but not as long as you would think.

It can be done but you have to have a way to shield one from the other, You can use something as simple as Air craft fuel tank sealer or Tar Paper but the two will start eating each other where they touch if you don't. A couple coats of epoxy over the frame May even work, Just depends how you attach the skin to the frame.
Dennis B.
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Fri Mar 10, 2017 6:40 am
Thanks, Dennis, I actually used "Gorilla Tape" around the flange before I hammered the aluminum skin over it. Hope it holds up!
The hood sides had to be concave, and also cured front to rear. A bit tough doing this on the Wheel, but I used a go kart wheel on top, so it wouldn't stretch the aluminum, just curve it. I had TONS of trouble with the welding and hammering afterwards on this. Kept cracking on me. Even bought a gas welding kit, and tried that to keep the aluminum softer. Finally found out the metal supplier gave me the wrong alloy, 6061, instead of the more malleable 3003.
The owner wanted a dropped center for the hood, and on the sides of that, two long oval vents, similar to another Aston Martin model. I had him mark off where he wanted them, and made the vent holes using a hammerform. I hammered the flat sides of the holes, but used a rounded off pry bar to get into the tight curves.
Attachments
astonhood_4.jpg
astonhood_3.jpg
astonhood_2.jpg
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