Saturn Door Removable Door Skin

Published 3/10/2010 - Bodywork

  Design Idea - Saturn Removalable Door Skin
A quick video on how to remove the door skin

On the Diablo since the doors are really hard to work on once completed, we decided to do a removable door skin.  Below is a video on the removable door skin from Saturn as a reference.
 
Research Tasks:
  • Review the mounting system and determine if any parts can be used
  • Review the trim molding mounting


 Building the Fender Well Liners!

Published 3/10/2010 - Bodywork

  Design Idea - Building the Fender Wells
Building the Fender Wells is much easier than we thought!

After speaking with lots of people who have built the Diablo Roadster, only a few actually did the fender wells.  Frankly they are really needed.  Here''s the best way to do it.  Go to Lowes and pick up the following materials:
 
Lowes Materials List:
  • Reinforced Fiberglass Plastic Sheeting which comes in 4''x8'' sheets
  • Flat stock steel to create the bars and wheel well arches
  • Various nuts and bolts for mounting the well well fiberglass plastic

Recommendations:

  • Build the wheel well liners in two or preferrably three pieces
  • Use stainless steel bolts and they will need to be power coated black.
  • Use washers and also rubber washers to isolate noise.
Pictures: (click to expand the view)
 
 
 
 
 


 Video of Diablo Door Assembly

Published 7/29/2009 - Bodywork

* Tech Tip - Title of tip *

Category: Bodywork

Subject: Build and assembly of Diablo Doors

Details: Another builder provided this YouTube clip

 

 

I have been researching the build of the Diablo doors to compile a resource of how it should be done.  Arguably there are many methods.  I have been reviewing these to come up with a simplified method.  Here''s a video clip below of one method for the D&R Roadster which is faily common.  Some areas can use improvement, others are well done!

 Picture of the details:


 Rear Bumper Mounting

Published 7/24/2009 - Bodywork

  Rear Bumper - Mounting Info for Rear Bumper
An elegant method of mounting the rear bumper

In review of different methods on mounting the rear bumper, I was fortunate to come across a real Diablo mounting.  The pictures below are how the bumpers are mounted on the Diablo Roadster and the SV edition Roadster.  Basically there is a mounting adapter which is attached to the fiberglass bumper with bolts welded to it.  The bolts pass through the holes on the frame of the car and washers and lock nuts hold it on.  Really simple.  See pics below:
 
 
 
To run the lights, simply drill out the areas and fish the wiring into a black wire loom and connect it with waterproof molex plugs.  This makes the rear bumper incredibly simple to do.
 


 Hard top design

Published 7/20/2009 - Bodywork

  Removable Hard Top - Simplifying the Overall Design
The hard top design made simple!

Developing the Roadster hard top is an effort in simplicity of design.  The original hard top was plagued with lots of issues.  Latch pins didn''t work, hard tops flew off at speed.  Overall a bad design.  Why replicate a poor design and we can clearly do better.  Here''s the simple steps to building a solid hard top which is light-weight and reliable too.
 
Overview of steps:

1. Form fit the inner shell to the windshield and the rear targa bar.  This is done after the center section is removed. 

2. Create a template with tape for the flat steel 1 1/4" stock and square 1/2" stock bars on the side.

3. Next, clamp down each side to make sure the conformity is met.

4. Create the steel to handle the rear pins for the latching mechanism for the rear decklid.  We'll use a different style of latching system for the hard top as we progress forward.  The old spring clip latches are not very secure.

5. Create the metal frame similar to the one shown below including the pins for the front A-pillar locations.  Be sure to construct the frame with pins for the front and using 8115, glue in the entire frame with the shell securely clamped down.

 

6. Create the rear pin locations for the hard top.

 

 

7. Create the mounting points on the rear decklid for mounting the hard top.  You want to do this before the final shell is fitted since you can make adjustments to any of the steel support work prior to gluing.  See pics below. 

 

 

 

8. Here's the front receivers for the pins for the hard top.

For the latching mechanism, this is where a Pontiac Trans-Am T-Top assembly comes in REAL HANDY.  Here's some pics below.  The idea is to use ONLY THE REAR ASSEMBLY of the latching mechanism.  This allows for a very secure and LOCKABLE hard top.  You simply won't have a hard top ejection on the highway.  Here's the pics below:

 

 

 

Project Tasks:
  • item/task
  • item/task
Open Issues: 


 Rear Tail Lights

Published 5/11/2009 - Bodywork

Rear Tail Lights
SUB HEADING

Reworking the rear tail lights is done in several steps.  Basically cut out the old tail lights and re-use the bezels.  These bezels will be re-done into removable bezels similar to what is shown below.



Here I have begun work on the rear lights. The body supplied for my car is a generic one. Up until you begin fitting the body and things like boot lids etc, it could be any number of different models. The rear lights hence are formed for the earlier models, and so the later style Diablo 6.0 surrounds do not fit without some rework.

The first thing to do is to place one of the surrounds roughly into the right place, and draw round the inside of the two circles with a marker. I then used a dremel with a plasterboard cutting tool, to cut these circles out. You should make sure the holes you cut are much larger than the actual holes you drew. I made mine at least a centimetre larger all round. You don''t need to be too tidy, as this will not be seen once the light surround is installed.

The next thing to do is once again taking a dremel, remove the raised section on each recess. You can see one at the top left hand corner of the light recess in the picture. Once I had carefully removed the unwanted material, I taped the back of the open hole with electrical tape, and filled the void with fibre glass bridging paste. Once dry, it can be sanded down, and you now have something to fill against to tidy up the rest of the surround.

I completed both sides, but have only taken a picture of one, The process is identical for that side.


Here I have made brackets from lengths of stainless steel, drilled and bent them to hold the rear lamp holders into the light surround.

The brackets are glassed into the sides of the surround, after first roughing up the metal and the surround to ensure a good bond. Stainless steel is a good choice for parts embedded in fibreglass as it cannot corrode. When steel rusts, it expands and this can cause cracking and distortion.


I have bonded strips with 6mm bolts welded to them into the surround here to facilitate mounting to the body. There are six mounting points in total to ensure the surround is pulled nice and tight against the body. I did consider bonding the surround directly into place on the body, but I wasnt sure I could get a good enough fixing for what is a fairly exposed location.

The surrounds do not look very pretty from this angle, but thats not so much of a problem as the reverse part will be totally covered when the surround is installed. I am currently on my third tub of fibreglass bridging compound, its just too useful and much stronger than body filler. Its useful for building up big differences and is less messy than conventional fibreglass. Its difficult to sculpt it however, and provides a pretty rough finish when compared to fibreglass matt. The other thing I like about it is its cure time. When mixed correctly, you can be grinding it back down after 15 minutes, although I usually wait until its stopped giving off heat which indicates its stopped curing (i.e. going hard).



I have bolted the surround into place here. The glass fibre paste is very strong stuff, and it needs to be because the bolts pull the surround to the body distorting it to match. This isnt actually a bad thing, and once the surround is pulled directly against the body, everything matches up pretty perfectly.

These surrounds are a new type different to those parallel usually supply. Its overlong to allow you to trim it to size. I have not finished the edge on the left because I am not sure how the grille will locate between the light surrounds, so I will leave this part for the time being and move onto other things.
One thing that is apparant is the light surrounds are very highly finished. If you wanted black surrounds, you could leave almost them as they are and they would pretty good. Unfortunatley mine need to be the same colour as the rest of the car so the first thing to do it to give them a good sanding to remove the glaze so that paint will adhere to them.


 Door Handles in Carbon Fiber

Published 4/30/2009 - Bodywork

  Doors - Carbon Fiber Door Handles
Replacements for the crappy handles provided by Lambo

These handles were molded from the factory handles in carbon fiber.
 


 Video - Removable Door Skins

Published 4/7/2009 - Bodywork

* Tech Tip - Title of tip *

Category: Doors

Subject: Removable Door Skins!!

Details: Here''s a video clip from an engineer who figured out how to do removable door skins for the Diablo. The outer door skins can be removed for access to internal parts servicing.  It''s a nice trick and worth looking at.

 

 


 Video - Door Strut Seal System

Published 4/7/2009 - Bodywork

* Tech Tip - Title of tip *

Category: Doors

Subject: Door Strut Seal Solution

Details: This is one way to seal the door strut through the front of the door.

 

 

 


 Body and Chassis Assembly

Published 2/9/2009 - Bodywork

Body and Chassis Come Together At Last!
The long awaited assembly

    I got more parts on the way to you. I found the fuel filter brackets in stainless steel. They are shipping them to me and I’ll forward them to you. Found more parts sources as well. Reviewing them for lighting, rubber molding, interior trim, etc.. Here’s some notes before the body meets the frame:
 
Before the body goes on:
  1. I know Mike is labeling all the wires and testing everything, I’m also looking for any connectors, etc.. which he might need. If you think of anything you need let me know ASAP and I’ll get it.
  2. I was told by another builder that we should test the air lift system before the body goes on. He made the mistake on his and it was a real pain to work on with the body in the way.
  3. Jeff mentioned about the rear grill and mesh screen being fitted before mounting the body.
  4. If any areas need more insulation along the chassis, we should do it now.
  5. I was recommended by two builders to use automotive dampening stuff like Dynamat on the body to reduce the hollow sound and make the car seem more solid and reduce road noise. If we have it, I’d like to do it. Just makes the car more solid. If the body is off the car it might be easier to do however I don’t know where all the points are that we need to glue when it’s attached to the chassis.
  6. Do we need to run the fuel system tubes to the tank before we mount the body? If I change the gauges to the carbon fiber ones I showed you, it will probably need a different sender, will this be a problem to access with the body on but the engine out of the car?
Body mounts to the chassis:
  1. I was recommended to glue the chassis and wait 24 hours until it’s completely cured.
  2. Once cured, the windshield frame would be the first thing to start on I assume. Once the windshield frame is mounted and windshield is test fitted, we can cut out the center fiberglass support.
  3. I know there will be additional steel welded in along the windshield frame and along the hard top targa bar. By this week, the parts for the firebird t-tops should arrive to help in the design aspects of the hard top solution.
  4. Once the t-tops arrive, we can send them out to have the mechanical parts stripped from the glass. We can use the parts plus the receivers to build the hard top solution.
  5. With the body fitted, the rear decklids can be worked on and mounted.
 
The next two-three weeks will be a lot of work and a lot of results will show.
 


 Removable Hardtop assembly notes

Published 1/22/2009 - Bodywork

Removable Hardtop
Assembly notes and build ideas

After the on-site review meeting regarding the car, we evaluated various latching assemblies and the ideas of making a special latching system.  We discovered that the Pontiac Firebird F-body car from 1983-1992.  The latch mechanism and the receivers will mount into the A-pillar and B-piller of the car.  The pins for the decklid being held down onto the engine cover when removed would be from ProTex latches.
Below are the parts lists for the roof and the rear decklid mounting solution.

For the front I took the hardware off of f 88 Nissan 300zx and for the rear I took it off from a 90 Jaquar front hood latch. There are lots of other application you can use and work with. I chose these application because the hardware are compact and not too boggy...
 
The pin type are two front pins are just slide in and nothing to strap down from the windshield heard to the hard top.   The style is just is like OEM style. I believe only the pins type latch allow you the lock down the hardtop to the engine deck, just like the OEM.
Review the photos under the NAERC Build Diary for reference on how to set this up.  It uses a pin latch style. It is very clear and simple how to build the top.  Use a frame to add rigidity.  Sandwich the two pieces of fiberglass together and form fit the pieces to the car.  Also use foam fill to make the top more solid.
 
Front slide in pins(back push it forward), and rear lock in pins(from top, push it down).  The frame should use hollow box steel tubing about 1/4" thick. 


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