1959 Peerless Restoration

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Larry Kluss
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Re: 1959 Peerless Restoration

Post by Larry Kluss »

Dean, I thought we determined the fender (wing) peak gently curved from the headlight back to roughly the center of the wheel well opening, then straight to the A-pillar corner?

Nice work on the rocker panel below the door. Reminds me of all the cut and paste work I did on the rear Sebring valance panel for the MGB. Pain in the A**.
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nigel c
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Re: 1959 Peerless Restoration

Post by nigel c »

here you go, long time since I really looked at it and its straight tip to screen....not really sure if it should be! :lol: :lol: :lol:


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Re: 1959 Peerless Restoration

Post by DaveC »

I'll take a picture of my ridge as I'm pretty sure the front is original. Actually, I'll send a picture of both sides as there's no way they're consistent...

dave
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Re: 1959 Peerless Restoration

Post by Larry Kluss »

Dave, confirmation from your car would be good. Dean and I were looking closely at this last weekend and it looks to us like Nigel is right, the peak should be straight. Though not the same body, the Warwick is also straight (or mostly straight with slight deviations :) ), and we know without question the Warwick is original.
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nigel c
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Re: 1959 Peerless Restoration

Post by nigel c »

I've been lookin through what I have fender linewise!
It's not something you take photos of really when you see another one but I have these two links that show the top of the wing on the Le Mans car (which was a very early car) and the front of my car 56 years ago!
not that clear and I guess you can interpret as you like but it kinda looks straight to me.

EBH

https://revslib.stanford.edu/catalog/xc310vy9153


BP

https://revslib.stanford.edu/catalog/hg822kw1172
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HealeyBN7
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Re: 1959 Peerless Restoration

Post by HealeyBN7 »

Nigel, That second link is helpful, not to see the fender line, but the front headlight...ah "features".

Using a little photo magic, I was able to straighten the image and place a few grid lines for reference. If the lines are straight we know that headlights are 7", so it looks like the right side fender/crown is dipped off 3/4". This makes for either a straight fender from the A pillar to the top of the headlight, (high headlight) or a slightly curved fender (low headlight). I guess they couldn't decide which was better, so you got both. There you have it.
front end from archive.JPG
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nigel c
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Re: 1959 Peerless Restoration

Post by nigel c »

yea they were down on the one side, do you remember me telling you it was a little like a Kit Kat? you can get two fingers on the top of one wheel and four on the other!
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Re: 1959 Peerless Restoration

Post by Larry Kluss »

Dean, also note the precise factory hood-to-body seams :)
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Re: 1959 Peerless Restoration

Post by VWNate1 »

I hope every one here remembers these were coachbuilt automobiles.....
-Nate
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Re: 1959 Peerless Restoration

Post by nigel c »

I hope everyone hear remembers they were trying to get them out the door as quickly as possible made from a product that only a handful of people knew how to use and non of them had made and sold cars before.......
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Re: 1959 Peerless Restoration

Post by DaveC »

Sorry for not posting the pics. I left for the UK before getting a chance. I'll do it when i get back.

Nige - was with my friends from Bromsgrove tonight, and we agreed that I need to come your/their way and spend some beer tokens together and see the cars.
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Re: 1959 Peerless Restoration

Post by nigel c »

so why do you always tell me in the past tense!
although not a good time at the moment as I have manflu :sick
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Re: 1959 Peerless Restoration

Post by HealeyBN7 »

I was on a roll, then the extreme temperature drop slowed me down. Still working on the body and getting close on the doors, hood and trunk (boot). I had to move the right side door rearward to ensure the window trim was centered on the opening. This opened the gap by the hinges, so the fender is getting some additional length.

I started to spray colored gelcoat. This will help guide me should I sand too deeply. I think the roof is done. The tops of the fenders and the license place box need attention next.
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IMG_4063.JPG
IMG_4063.JPG (116.46 KiB) Viewed 25808 times
IMG_4062.JPG
IMG_4062.JPG (87.11 KiB) Viewed 25808 times
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Re: 1959 Peerless Restoration

Post by HealeyBN7 »

The driver's driver's side aluminum drip rail was also on the fabrication list. Half if it was missing (cut in half at the door latch side) and so badly twisted that it could only be tossed and replaced. I looked for off the shelf "J" shaped drip rails, even bought some, but the Peerless has a softer curve and made from thinner stock.

I planned on making a roller/feeder/shaper, but it seemed like a lot of effort to machine the wheels, make the adjusters and roll out just one or two pieces or trim.

One problem was where to get the aluminum cut. I needed 1 5/8" strips of 3003 .030. The tricky part is they needed to be 7 feet long. I could bring home 8 foot sheets, but I don't have a 7' sheer. Hand cutting would look terrible as would the air sheers. I had not used Industrial Metal's fabrication services before, so with this small project I thought it was worth a try. I typed in 1 5/8 x 7' qty 6- (yes many spares) into the online order form and got a note back that they would be ready in 2 hours for $30.00. Wow that was easy. They were perfectly straight. I spent more in gas a lunch then material.

To make a jig, I welded a long rod to a square tube that I clamped in the bench. To form the metal, I used a combination of rubber mallets and careful yet purposeful blows. Eventually I created a long straight drip rail.

It took a little back and forth forming to get the window shape. The trunk drip rail is a bit more complicated, but eventually I got a shape that I can fasten to the car.

Tiny hammer marks were removed with 600 grit and the trim was polished on a buffing wheel.

My goal is to get the trim fully fitted (holes drilled) while the car is in primer to avoid paint damage (paint... yes that dream).

Not ready to hammer out a DB3, but it was fun...

Dean
Attachments
Jig
Jig
IMG_3955.JPG (117.61 KiB) Viewed 25808 times
Comparing a scrap to the Warwick
Comparing a scrap to the Warwick
IMG_3944.JPG (94.53 KiB) Viewed 25808 times
Test fit
Test fit
IMG_3941.JPG (99.78 KiB) Viewed 25808 times
Full trim piece before polishing
Full trim piece before polishing
IMG_3952.JPG (101.3 KiB) Viewed 25808 times
From the inside it looks like a window opening
From the inside it looks like a window opening
IMG_3951.JPG (103.32 KiB) Viewed 25808 times
Boot trim ( that no one will see)
Boot trim ( that no one will see)
IMG_3967.JPG (93.8 KiB) Viewed 25808 times
Boot trim waiting for the day it gets installed
Boot trim waiting for the day it gets installed
IMG_3969.JPG (95.46 KiB) Viewed 25808 times
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Re: 1959 Peerless Restoration

Post by VWNate1 »

Very, VERY nice ! .

One point : you will see that beautiful trunk drip rail every time you open the boot and trust me, it'll make you smile .
-Nate
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Re: 1959 Peerless Restoration

Post by tannyo »

Amazing! I'm really impressed by the quality of your work.
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Re: 1959 Peerless Restoration

Post by Martin Keller »

Hi Dean,

That is just amazing, your so talented, but what should one expect when they see the craftsmanship you have done on the rest of the car and the building that your working in.....those barn doors are just amazing and I remember that car sitting in a fenced area and thinking that there is not even enough left of it to restore......boy was I wrong plus I did not know you then and the abilities you have....just amazing.

:drive
Martin Keller
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Re: 1959 Peerless Restoration

Post by Larry Kluss »

I saw Dean's handy work on these pieces in person and they look fantastic. The amazing part to me is how simple the tooling is. The hardest part has to be having the patience to form compound shapes like that with just hand tools.

So how many hours do you have in those drip rails, Dean? :)
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Re: 1959 Peerless Restoration

Post by HealeyBN7 »

Larry Kluss wrote:So how many hours do you have in those drip rails, Dean? :)
If I was paying for the labor, probably $1,000,000 so far. Unfortunately they are not done until they are secured to the car, so I'll have to keep the meter running and let you know when I call it quits. :)

Dean
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Re: 1959 Peerless Restoration

Post by nigel c »

those drip rails have always been a worry when buying a car that has been dismantled. The number of times I have seen them folded in two so they fit in a cardboard box or the vendor dismisses them with a "oh them things, chucked them mate, they were no good buy the time I'd got them off"
Beautiful bit of work there Dean and If it wasn't for the shipping I think there's a market for them! :hammer: :hammer:

Going back a couple of your pages I'm looking at "improving" my door hinges (and finally getting round to wind up windows!) as we are touring this year in BP round the channel Islands and I thought I should really finish a few jobs off.....only been on the road 18 years....

MGB door hinges look to be the best (as you have used) but looking at your pics the bottom fixing inside the door...is that going to foul the door card/trim?

and were they as close (in the opening action) as they look to the originals?
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Re: 1959 Peerless Restoration

Post by HealeyBN7 »

The MGB hinges have proven to have been a good choice. The doors don't open to a full 90 degrees like the originals, but they are close to 85 degrees. It doesn't make sense when you look at the size of the door, but I find the Warwick a a tighter fit then it looks like it should be. The seat, pedals and steering wheel are a bit forward forcing you to fold up to get in. I expect that in the Lotus, as the doors are half the size. Maybe they had to do that for the rear seating access. Anyway the additional 5 degrees of door swing probably makes no difference. I usually get in and out with the door open no greater then 45 degrees.

I mounted the hinges as far apart as I could, so the bottom one is low, but still above the sill and the inside the door cavity. You could easily raise it a couple inches. I see no harm in that. Everything seems to clear at this point. Finger's crossed!

Dean
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Door fully open - sneak peak at the fender line coming together
Door fully open - sneak peak at the fender line coming together
IMG_4077.JPG (80.03 KiB) Viewed 25774 times
Driver's side
Driver's side
IMG_4079.JPG (100.13 KiB) Viewed 25774 times
Passenger side
Passenger side
IMG_4084.JPG (95.48 KiB) Viewed 25774 times
Passenger side with a paper pattern for the shut panel
Passenger side with a paper pattern for the shut panel
IMG_4086.JPG (111.42 KiB) Viewed 25774 times
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nigel c
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Re: 1959 Peerless Restoration

Post by nigel c »

lookin sweet my friend. The phase 2 had different hinges and they only open to perhaps 65* and is very noticeable when your used to the full 90* of a phase 1.
cracking development Dean and I think that's my route....after 30 years trying to modify these cars for the greater good I can thankfully retire and leave it in your capable hands.................. :bow:
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Re: 1959 Peerless Restoration

Post by nigel c »

oh, meant to ask, what format is your artwork for the ali door thresholds as I should really do something about these.............
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Re: 1959 Peerless Restoration

Post by HealeyBN7 »

I used Vinyl Master 4.0 as the software for this jobr. VM saves it in .vdoc format, whatever that is. Says that I can save it to SVG, AI, DXF, JPG and a few others. Tell me your favorite flavor and I'll send it your way...just get ready to pick and drink:)
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nigel c
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Re: 1959 Peerless Restoration

Post by nigel c »

A.I would be good. If you could save it in an older format it would help as I'm running Illustrator 5 or below!
If you cant not a problem as I can send it over to friends who can convert, Thanks buddy

I'm supprised you can save it as a jpeg as that's just an image? so it would have any defining edges/vectors etc??
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