How About a DIY Aluminum Interior Thread?

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Re: How About a DIY Aluminum Interior Thread?

Postby TSchommer » Sun Apr 30, 2017 1:08 pm

I have not been able to get too much done since I started this thread because of the bad weather up here most of the month of April. Mostly just trying to pull out all of the carpet without destroying it. Any tips for removal or cleaning the contact cement? Also, did anyone paint the raw fiberglass silver in some of the visible areas where there will not be any aluminum skin (mainly under the dash and foot wells)?

Did most of you just use the 063 aluminum on the floor? I'm thinking that 040 would be thick enough for everything, but I might use 063 for the floors. Or I could use 080 since we have so much of is laying around the shop in scrap bins.

Were there any areas in particular that caused issues? So far my initial observations seem like the toughest area might be the transition between the three hole door sill panels and the rear firewall, it looks like there needs to be a part with compound curves there. It looks like the front fender areas could be done with just a single curved panel.

I see lots of rivets in the photos, were the used as the main attachment method over glue, or mainly for show?

Beck668, on your tool recommendations you mentioned a seamer. Is that what you used to fold the metal for the flanges? I'm thinking about making a simple DIY brake like the one in the video below?

https://youtu.be/jCiOcKDFg7o

P.S. Mtflyr, if you get any top secret info from Beck668, please be sure to share! :)
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Re: How About a DIY Aluminum Interior Thread?

Postby beck688 » Mon May 01, 2017 3:36 am

As far as the seamer vs brake went. Harbor freight had a couple of brakes but the vice grip seamer worked fine for me. I have a piece of aluminum that is about 3x3x18" It is an extusion, has clean faces and 90 degree corners. I would make the bend with the seamer and then tighten the bend with a hammer and using the block of aluminum as an anvi, sounds harder than it is. .040 would probably work for the the floor I used 060 because I didn't want the floor to get all dented looking - I did this probably 10 years ago and and the the floor has held up perfectly. Really -- put the car on jack stands and TAKE THE FLOOR OFF and put the aluminum on it and reininstall. The advantages - takes very little time - lets you sit under the dash and clean up any wiring, makes the joints easier to work with at the floor wall junction, if you look in the engine compartment - that bit of floor get aluminum on it with rivets. As far as the rivets go all of my rivets hold hold two parts together. The most important thing is to be very carefull about spacing and alignment because they are so visible. I meant to take pictures I will get to it tonight. Not wanting to brag, but some of my solutions look pretty neat and tidy. I was at Caffeine and Exotics, C&Os by invitation car show. Even in the company of a bunch of really stunning cars - it shows very well. Even got a hug from a woman who said it looks like a car that is actually enjoyed. I'm o;d I an't got any secrets anymore. I promise I will get details of joints and panels.

TAKE THE FLOOR OFF TO DO THE ALUMNUM - use an electric drill with a nut driver, it's easy.
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Re: How About a DIY Aluminum Interior Thread?

Postby beck688 » Mon May 01, 2017 3:28 pm

A couple of pictures
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int1.jpg
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Re: How About a DIY Aluminum Interior Thread?

Postby beck688 » Mon May 01, 2017 3:32 pm

More The wheel wells are basically a sheet that wraps around - no fancy curves or cuts. I removed the middle cover because I did a new throttle and I haven't replace it.
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Re: How About a DIY Aluminum Interior Thread?

Postby TSchommer » Mon May 01, 2017 5:45 pm

Thanks for the additional detail photos and information. Your interior looks awesome, and you're right the wear on everything really adds to the authenticity.

Im wondering what are the two extra gauges, and what is the purpose of the red and yellow lights, it looks like they are on the passenger side footwell.
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Re: How About a DIY Aluminum Interior Thread?

Postby Mtflyr » Mon May 01, 2017 6:04 pm

Very cool, thanks Beck688. Keep the pic's coming. [8D]

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Re: How About a DIY Aluminum Interior Thread?

Postby beck688 » Mon May 01, 2017 6:33 pm

The gauges are cylinder head temp gauges. They are used for ultralight aircraft they were really inexpensive I made the thermal couples for a couple of dollars. The lights are for the oil and alternator. I used to build b and c sports racers in the 70s and it was customary to put big idiot lights on the dash. These are trailer clearance lights and I buried them down in the foot well - they will catch my eye but they don't take away from he period looks of the car.

It took about five years to find all of the parts for the Autopusle pumps.

I choose to call the dirt patiina - you can actually hose the interior off ( there are drain holes) and it can be cleaned with a household cleaner that is mildly abrasive -- too much abrasive will remove the oxidation and make it shiny unless shiny is what you are going for
Last edited by beck688 on Mon May 01, 2017 6:41 pm, edited 1 time in total.
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Re: How About a DIY Aluminum Interior Thread?

Postby TSchommer » Mon May 01, 2017 6:39 pm

Are you actually using the Autopulse fuel pumps? I thought that most people just installed them for the visual effect.
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Re: How About a DIY Aluminum Interior Thread?

Postby beck688 » Mon May 01, 2017 6:47 pm

They are just for looks I have bought and d sold about twenty and never found one that had a diaphragm that I would trust. I wish I could they are incredibly noisy -- adds to the ambiance during start up
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Re: How About a DIY Aluminum Interior Thread?

Postby gotowo » Mon May 01, 2017 8:19 pm

I did my interior a couple of years ago - still a work in progress as I need to finish the tonneau and a few other bits. There is a lot of time and effort to get the correct shape
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6 pattern.JPG
2 pattern.JPG
1 pattern.JPG
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Re: How About a DIY Aluminum Interior Thread?

Postby gotowo » Mon May 01, 2017 8:21 pm

Here are the side panels
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skin3.JPG
skin2.JPG
2 x inserts.jpg
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Re: How About a DIY Aluminum Interior Thread?

Postby gotowo » Mon May 01, 2017 8:23 pm

some interior shots
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photo 2 copy.JPG
photo 1.JPG
photo 1 copy.JPG
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Re: How About a DIY Aluminum Interior Thread?

Postby gotowo » Mon May 01, 2017 8:24 pm

More interior shots
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photo 4.JPG
photo 3 copy.JPG
photo 2.JPG
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Re: How About a DIY Aluminum Interior Thread?

Postby gotowo » Mon May 01, 2017 8:27 pm

final shots
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IMG_4560.JPG
IMG_4559.JPG
IMG_4558.JPG
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Re: How About a DIY Aluminum Interior Thread?

Postby gotowo » Mon May 01, 2017 8:37 pm

Before I did this, I had only done a weekend workshop on basic panel fabrication. If you are considering doing aluminium work, it is well worth getting to understand the basics and what tools to use - very helpful

I still need to finish this tonneau - I have a split in the aluminium and need to learn how to weld now!
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