1965 Valiant Custom 200 - Creating the Header Seal Retainer

[Tom Bishop]

Receiving Valiant without Gearbox, Prop shaft and many other missing parts, the strip that holds the roofs rubber seal to the windscreen was gone.

With no idea on how it should look, I scoured the net looking for pics and Ideas. @66Dvert also provided me with dimensions.

This is the Journey on how I recreated the Part.

First a template was created by sticking masking tape to the the curved surface. The Curved surface would have a very different shape when flattered out.

 

[Tom Bishop]

The Masking tape templates were scanned and turned into a CAD version.

This was then printed on paper, reinforced with layer of masking tape so the paper would not distort and tested.

A cross section was also created

 

[Tom Bishop]

The CAD versions were turned to a Jig.

After being CNC cut the holes and edges needed to be cleaned up.

 

[66Dvert]

the start looks good, but it is a difficult part to make and don't forget the "wings" that fit on the sides.

 

[Tom Bishop]

Then I needed to halt Valliant's build and prep Thingi for her Adventure around Southern Africa.

We completed the rally and 1000+ pairs of shoes were fitted to the feet of underprivileged school kids in Zambia.

Rested and eager it was time to turn the ideas to product.

 

[Tom Bishop]

First the strip that holds the rubber seal.

From a sheet of 1mm plate, the shape was cut out and formed with the jig.
To end, the jig need to be broken out of the "C" shaped profile.

 

[Tom Bishop]

Testing to see how the profile holds the rubber bit. It does it well.

Then fitted to the bulkhead and checking how it all comes together at the windscreen.

 

[Tom Bishop]

Next the part that will cover / hold the ragtop end in place.
To simplify the profile and to make the two parts independently adjustable, I chose to make this a separate part.

Again from a 1mm piece of plate.

Cut out roughly, trimmed to the line and formed.

You need to watch metal. It quickly goes out of shape, needing you need to bring it back to what you are wanting. After flattening the seam, there was too much arc in the shape, needing the inside curve to be streched to get it all back to the shape of the jig.

 

[Tom Bishop]

Ragtop part finished off and test fitted to the bulkhead.

The profiles are now held to the bulkhead with M4 screws and rivnuts.

All screwed together and checked.

It works.

Next the parts must go for plating.

 

[cudamark]

Wow, that looks like it was a lot of work! Are you going to make them for sale?

 

[66Dvert]

Super nice job. I'd like to test out /use your 2 part idea. for one of my test mules that I use for parts.

 

[65Dart67300]

Take my money, please!

 

[Tom Bishop]

Wow, that looks like it was a lot of work! Are you going to make them for sale?

Sorry.. Will not be making any for sale.

Playing with cars is just my hobby.

 

[Tom Bishop]

With the parts back from plating, they were fitted and the rubber seal installed.

Another task that can be ticked off in the build.

 

[66Dvert]

With the parts back from plating, they were fitted and the rubber seal installed.

Another task that can be ticked off in the build.

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that's some DAmn fine work!

 

[65Dart67300]

Sorry.. Will not be making any for sale.

Playing with cars is just my hobby.

Would you consider making the cad files available? I'm sure it will be helpful for those that want to duplicate your process.

 

[Tom Bishop]

Would you consider making the cad files available? I'm sure it will be helpful for those that want to duplicate your process.

Sure, not a problem.... Just need a bit of help on how to upload the DFX files.