Peugeot 205 Saloon Libre - RWD Space-Frame Silhouette Racer
Discussion
Soooooo.. It's been almost a month since my last update! I moved house a couple of weeks back so got caught up in all the monotonous bullcrap that generally accompanies such things, then spent a week at the 'ring for DN10!
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/GOPR1017e_zps214d199c.jpg)
I'm about to go full steam ahead in to the bodywork, so yesterday I trimmed the non-sunroof skin that I've had kicking around for.. about a year. Removing all the.. everything.. from it, leaving me with just the skin.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_002_zpsa5aecc1a.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_004_zpsd5d616bd.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_005_zps67375381.jpg)
Since I'll be moulding the skin, I couldn't go drilling out spot welds from the top, which would have been easy. Instead, I had to trim everything and remove spot welds from underneath, making the whole process a lot more fiddly.
Anyway.. with that done, I drilled / chopped the sunroof skin off my shell and binned it.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_006_zps8617a93b.jpg)
Then today I set about trimming the rear quarter panels from my rear shell half. These were the only bits I wanted to keep, so was pretty liberal with the grinder on everything else!
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_002_zps1cf28c6b.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_003_zpsba7c4819.jpg)
The following bit will make sense later, but I needed to tidy up the tops of the quarter panels, above the doors, as this is where the roof join will be.
A little bit of Cardboard Aided Design..
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_004_zps65fe19ef.jpg)
Then replicated in steel and welded up.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_005_zpseab66d8c.jpg)
Finally, dressed the welds back to a nice radius.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_008_zps13924bda.jpg)
The last thing to do was tack on the lower parts that I had cut off ages ago. I wish I had never done it, to be honest, but plans change and my idea for the rear body is much better now than it was then!
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_009_zps06ea2634.jpg)
And all done.![smile](/inc/images/smile.gif)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_011_zps86105d2b.jpg)
Things will hopefully be pretty fast-paced from here.. I have a deadline for September, whereby I want the chassis in powder coat and the bodywork all done ready to be reproduced in carbon!
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/GOPR1017e_zps214d199c.jpg)
I'm about to go full steam ahead in to the bodywork, so yesterday I trimmed the non-sunroof skin that I've had kicking around for.. about a year. Removing all the.. everything.. from it, leaving me with just the skin.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_002_zpsa5aecc1a.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_004_zpsd5d616bd.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_005_zps67375381.jpg)
Since I'll be moulding the skin, I couldn't go drilling out spot welds from the top, which would have been easy. Instead, I had to trim everything and remove spot welds from underneath, making the whole process a lot more fiddly.
Anyway.. with that done, I drilled / chopped the sunroof skin off my shell and binned it.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140712_006_zps8617a93b.jpg)
Then today I set about trimming the rear quarter panels from my rear shell half. These were the only bits I wanted to keep, so was pretty liberal with the grinder on everything else!
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_002_zps1cf28c6b.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_003_zpsba7c4819.jpg)
The following bit will make sense later, but I needed to tidy up the tops of the quarter panels, above the doors, as this is where the roof join will be.
A little bit of Cardboard Aided Design..
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_004_zps65fe19ef.jpg)
Then replicated in steel and welded up.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_005_zpseab66d8c.jpg)
Finally, dressed the welds back to a nice radius.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_008_zps13924bda.jpg)
The last thing to do was tack on the lower parts that I had cut off ages ago. I wish I had never done it, to be honest, but plans change and my idea for the rear body is much better now than it was then!
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_009_zps06ea2634.jpg)
And all done.
![smile](/inc/images/smile.gif)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/WP_20140713_011_zps86105d2b.jpg)
Things will hopefully be pretty fast-paced from here.. I have a deadline for September, whereby I want the chassis in powder coat and the bodywork all done ready to be reproduced in carbon!
CamMoreRon said:
Thanks chap! ![smile](/inc/images/smile.gif)
I ruined my phone last week so can't take any pictures unless I manage to find the charge lead for my digi camera. The front bodywork is on now.. looks bloody awesome.![biggrin](/inc/images/biggrin.gif)
I hope you find the charge lead then! Love this thread and can't wait to see more. Amazing project and very very impressive!![smile](/inc/images/smile.gif)
I ruined my phone last week so can't take any pictures unless I manage to find the charge lead for my digi camera. The front bodywork is on now.. looks bloody awesome.
![biggrin](/inc/images/biggrin.gif)
Thanks chaps. ![smile](/inc/images/smile.gif)
It was late last night and I needed feeding so here's the detail I missed out:
During the week I fiddled aroung getting the wings and bonnet aligned and then tacked them on to the jig, then borrowed the bumper / valance from my resto GTI and bolted it on to get the lower line of grille & lights right. I temporarily stuck the grille in place with my glue gun to get the headlamp voids.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03467_zpsa178d8d0.jpg)
Then made some rough cardboard templates for the light / indicator blanks, and used the standard parts as patterns to get the form right. I don't have any sheet metal forming tools yet, so had to make do with some 3" bar stock in the vice, a mallet, and a stack of welding gloves to form the compound curve.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03494_zps0a8a0452.jpg)
Then welded some flanges to them for stiffness.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03495_zps9ab2ddc2.jpg)
And tacked them to the bonnet.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03498_zps4bfde4dc.jpg)
Difficult to see, but they have a very slight compound curve.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03504_zpsef6b203c.jpg)
Then a similar story with the indicator blanks.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03570_zps368c3f36.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03572_zps370e0e4f.jpg)
Not perfect, by any means, but they're as close as I could get! They'll need a skim of filler anyway as the pattern bonnet's shape doesn't quite match the wings.
![smile](/inc/images/smile.gif)
It was late last night and I needed feeding so here's the detail I missed out:
During the week I fiddled aroung getting the wings and bonnet aligned and then tacked them on to the jig, then borrowed the bumper / valance from my resto GTI and bolted it on to get the lower line of grille & lights right. I temporarily stuck the grille in place with my glue gun to get the headlamp voids.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03467_zpsa178d8d0.jpg)
Then made some rough cardboard templates for the light / indicator blanks, and used the standard parts as patterns to get the form right. I don't have any sheet metal forming tools yet, so had to make do with some 3" bar stock in the vice, a mallet, and a stack of welding gloves to form the compound curve.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03494_zps0a8a0452.jpg)
Then welded some flanges to them for stiffness.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03495_zps9ab2ddc2.jpg)
And tacked them to the bonnet.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03498_zps4bfde4dc.jpg)
Difficult to see, but they have a very slight compound curve.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03504_zpsef6b203c.jpg)
Then a similar story with the indicator blanks.
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03570_zps368c3f36.jpg)
![](http://i30.photobucket.com/albums/c302/supermuff/205%20Project/DSC03572_zps370e0e4f.jpg)
Not perfect, by any means, but they're as close as I could get! They'll need a skim of filler anyway as the pattern bonnet's shape doesn't quite match the wings.
It won't be a flip front as such, but the front end will be removable in one piece for best access to everything. Engine access will be a bit tricky as it's so far under the windscreen, but I'll have the trans tunnel panels removable so you can get to things at the top / back of the engine. Any major work will be an engine-out job to do properly, but that's just how it is!
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff