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Thread: Project Alan Mann

  1. #81
    Spanner Monkey

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    Re: Project Alan Mann

    Hi again,

    CheeRS for your help ryan.minshall, qcadta, M11rf for the advice on the guards
    Been off for about a month from a footy injury. Started to come right again so I had a crack at the four link this afternoon






    Cut my holes after many measurements and folded the tabs up
    Will try get the other side in next weekend, running out of light now with winter looming


  2. #82
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    Re: Project Alan Mann

    Got the other side in at the weekend









    Just need to paint them and put the link bars in and I'll post a few more pics


    I've been wanting to fit the front panel for a while now but want to put some holes in first just like this below



    I made up a tool at work to try swage them



    Used the holesaw on my old front panel to sort out the hole size and spacings
    opted for 3'' Hole and 50mm spacing between them to make 5 holes in total



    This was the swage the tool was producing today, not bad for a Prototype but we'll do bit more maching to get a bigger swage I rekon


  3. #83
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    Re: Project Alan Mann

    Finished the 4 Link

    All painted


    No more leaf springs


    Marking out the front panel


    Pilot Holes


    Holesawing through the front panel


    Using my Homemade Press Tool


    The Result


    Prepping for Paint


    Finished product


    5 x 3'' Swaged holes


    Welded on


    Done for the weekend

  4. #84
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    Re: Project Alan Mann

    That's looking great, very nice work with the swaging

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  6. #85
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    Re: Project Alan Mann

    Nice work and very good looking !!! Keep it up !!!

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  8. #86
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    Re: Project Alan Mann

    looking ace mate them holes look nice, bit to big for my little peck peck tho , keep up the work mate cracking

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  10. #87
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    Re: Project Alan Mann

    Ive seen Swaged holes done inside a few cars so thought I'd give it a go
    Drew an idea up on an old door and liked what I saw
    So Ive turned my car into Swiss Cheese




    Marked out, Centre popped and pilot drilled 70 holes!



    This made light work of cutting the 2" holes



    Hydraulic Chassis punch I pinched from the sparkys at work



    Done for the night, 70 holes punched



    My homemade swaging kit



    swage tool in action



    The Results






    One swiss cheese Mk1 Complete, Whatcha rekon?


  11. #88
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    Re: Project Alan Mann

    Looks great mate...

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  13. #89
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    Re: Project Alan Mann

    Holy moley Starting to look like a racer now

    Crack on and keep up the good work

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  15. #90
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    Re: Project Alan Mann

    did you keep the scraps so you know how much weight you have saved?

  16. #91
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    Re: Project Alan Mann

    Looking great - keep up the great work, and the updates

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  18. #92
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    Re: Project Alan Mann

    Quote Originally Posted by 89fordguy View Post
    did you keep the scraps so you know how much weight you have saved?
    Haha sure did, it was like 4 or 5kg. Not much but I guess it all helps

  19. #93
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    Re: Project Alan Mann

    Bubble Arches

    Spent the past two weekends fitting my fibreglass bubble arches.

    Heres my attempt









    Forming the new tubs



    Trimmed to size and stitch welded



    Drivers side Tub



    Wasnt sure about this one...Do you completely seal up the gap between outer edge of the tub and the inside of the arch?
    I was thinking of just using seam sealer






    They are just screwed on for now so I can take them off and paint under the bubble arch
    but in the next few weeks I'll be riveting them on and blending them in.



    The Finished product...for now







    Collage of the process


  20. #94
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    Re: Project Alan Mann

    great job so far.....good choice for a replica, doubt there are many alan mann replicas over that side of the world

  21. #95
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    Re: Project Alan Mann

    Hey mate, looking great - keep up the great work and updates

  22. #96
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    Re: Project Alan Mann

    Personally I would stitch the new outer tub to the old inner, but that's just me. I would be concerned that the seam sealer would flex and crack with so few tack welds.
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  23. #97
    Mechanic davblue's Avatar

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    Re: Project Alan Mann

    just went thu ur profile of build
    nice work there to detail.
    sure doing a good job
    keep it up.

    ds restos.

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  25. #98
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    Re: Project Alan Mann

    Looking good, well done so far...

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  27. #99
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    Re: Project Alan Mann

    looking very good keep going

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  29. #100
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    Re: Project Alan Mann

    Looking very nice
    The 4-5kg will help just think about all the extra food you can eat this Christmas

  30. #101
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    Re: Project Alan Mann

    Quote Originally Posted by mk1van View Post
    great job so far.....good choice for a replica, doubt there are many alan mann replicas over that side of the world
    CheeRS unfortunately last year at a motorsport event not one but two alan mann replicas appeared



    They were both running YB's aswel, so Ive got some tough competition



    But neither of them were road legal, so hopefully mine will be the only one on the roads over here

  31. #102
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    Re: Project Alan Mann

    More Rust Repairs today

    Put the roll over jig back on and flipped the car on its side



    Gave the spare wheel area a wire brush to find this



    made up a new piece









    Done what you suggested "exboyracer" and stitch welded around the tubs



    Running out of light again



    What should I put between the edge of the tub and the fibreglass arch?
    Some people have suggested a rubber strip? or should I just use seam sealer..? or both?




    and "xygtho" you'll have to come over and have a look, I didnt realise you were living so close, I'll PM you

  32. #103
    Spanner Monkey Turbosport Subscriber

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    Re: Project Alan Mann

    What should I put between the edge of the tub and the fibreglass arch?
    Some people have suggested a rubber strip? or should I just use seam sealer..? or both?




    You shouldnt have to put anything between them

    if youve enclosed the hole up with the tub so no mud or water can get into the car through the wheel arch tub then it should be fine
    just trim back the extra tub metal and seam seal the tub

    Youll just get mud and water up there which shouldnt be anything to worry about if its cleaned regularly

  33. #104
    Bodger

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    Re: Project Alan Mann

    and "xygtho" you'll have to come over and have a look, I didnt realise you were living so close, I'll PM you[/QUOTE]

    Sounds like a plan Escort74

  34. #105
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    Re: Project Alan Mann

    Just looked through your thread and hats off to you doing the work your doing looks great keep up the good work.

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  36. #106
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    Re: Project Alan Mann

    CheeRS Gazz Cossy and the other guys following my thread, all the positive feedback and helpful tips are much appriciated



    Been doing a few more rust repairs on the sills and finished off the tubs this weekend







    Painted with POR15








    Next thing is the watts linkage, do I try make one or buy one...

  37. #107
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    Re: Project Alan Mann

    looking good and getting wider by the week .

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  39. #108
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    Re: Project Alan Mann

    Watts Linkage

    I've toyed with the idea of six linking the Escort for a while now but Watts Linkages are too pricey over here so I've tryed my hand at making my own

    My Plans



    Parts coming together nicely



    Prototype almost finished



    Prototype



    Prototype



    Mocked it up on the car for the first time



    All appeared to fit so I took it back to work to make it look a bit prettier "Prototype 2"



    Happy with that I sent my parts off to get gold passivated



    Almost finished product, added in some gussets too









    More Swaged holes, I couldnt resist


  40. #109
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    Re: Project Alan Mann

    Skid Plates

    Also made up some strengthening plates to go between the sills and Chassis, with some help from "xygtho"





    You'll have to come over and see it soon Allan

  41. #110
    Spanner Monkey Alan G's Avatar

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    Re: Project Alan Mann

    Excellent work on the watts linkage!

    This will be a project I'll be watching closely!

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  43. #111
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    Re: Project Alan Mann

    Brilliant stuff there....that is going to be a very special car.

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  45. #112
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    Re: Project Alan Mann

    Looks the dogs nuts well done!

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  47. #113
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    Re: Project Alan Mann

    WOOOO that looks cracking job you have done .

    Still going with the Alan mann colours after seeing all the replicas down there.?

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  49. #114
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    Re: Project Alan Mann

    Quote Originally Posted by essyrwd View Post
    WOOOO that looks cracking job you have done .

    Still going with the Alan mann colours after seeing all the replicas down there.?
    CheeRS essyrwd, I did toy with the idea of the broadspeed blue and silver scheme but I think I'll keep to the original plan. Im planning to keep this thing road legal so I doubt I'll see another one like mine on the street...i hope

  50. #115
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    Re: Project Alan Mann

    Thanks again guys for all the positive feedback, helping to keep me motivated!

    Been busy these past two weekends finishing off the watts linkage

    The Cars back on its roof to make the fabrication a bit easier










    Made up a small tunnel to house the watts linkage, should give it some clearance as it was looking pretty close to the floor





    Welding in the gussets



    Cleaned up the front panel as a bit of cancer was spreading



    Even the girlfriend came round to help out



    Diff/Floors/Boot got a lick of POR15







    All put back together






    Packed up for now.




    Heading back home to the UK for a couple of weeks to attend a funeral.
    On a good note though, I'll be travelling light and returning home with a whole load of goodies for "Project Alan Mann"

  51. #116
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    Re: Project Alan Mann

    Looking good now mate
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  53. #117
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    Re: Project Alan Mann

    Mate, that Watts linkage looks awesome - I knew you could do it

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  55. #118
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    Re: Project Alan Mann

    Quote Originally Posted by xygtho View Post
    Mate, that Watts linkage looks awesome - I knew you could do it
    Ditto, that is looking very nice mate, I hope the trip back to the UK goes as well as it can for you

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  57. #119
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    Re: Project Alan Mann

    Loving the pic of your two cars under the car port

    Cracking watts ,should defo get rid of the rear end steer

    What part of wet ,windy and flooded uk you coming too
    Bring a brolly and some wellington boots
    Last edited by essyrwd; 25-11-2012 at 09:35.

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  59. #120
    Spanner Monkey

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    Re: Project Alan Mann

    CheeRS Guy's! "essyrwd" I was staying in London but when I went up to Huntingdon for the funeral I definitely needed those wellies. The flooding up there was madness

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