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Joined: Dec 2011
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Originally Posted By Hamwich
Tracing the outline of the old wing onto cardboard and then cutting out the shape to make a template to trace it onto the new wing is an easy task.

But: the challenge is where to tape the template onto the new wing? Not only is the new wing wider than the old, but I also want to adjust the finished width to add in an extra 6mm or so.

So Button's cunning plan of establishing a datum line down the wing is a good one. I can then work off that to establish a reference from which I can displace the template by a consistent amount.

The last challenge is to ensure that the datum line is in the same relative position on both wings.

That's where Simon's recommendation of using the 3D printer to make a jig comes in.

Here's the plan:

1. Print out a simple pantograph that holds a pen at an adjustable distance from a base edge
2. Put a stripe of masking tape down the old wing where I want the datum line to go
3. Run the pantograph base down the outer edge of the wing, marking the datum line along the masking tape at a fixed distance from the outer edge.
3. Tape a strip of heavyweight paper with the edge aligned to the datum line on the old wing
4. Trace out the inner edge of the old wing onto the paper
6. Cut along the profile line to provide a template
7. Run the pantograph along the new wing to replicate datum line on the old wing
8. Adjust the pantograph to add the extra width
I want and run another datum line down the new wing
9. Use the new datum line as a base line for the template and transfer the required profile to the new wing
10. Take my trusty disc cutter and trim off the unwanted bit of wing

Hopefully I won't require step 11

11. Ring up Sid Watson and ask him to make me another wing smile

More news at the weekend, I have to do some actual work for a few days...


Yes just as I thought. Sure glad I could help (oops).


Button
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Started the scary bit today, trimming the left wing. First step was to mark up and measure the old wing (on the right) so I could make some templates to transfer the profile to the new wing (on the left)



Then I added a safety margin and made a cut, offered up the wing, saw where it needed trimming , and tried again.

After 4 trial fits and trims, I'm nearly there, but I'm knackered and the batteries for the disc cutter are flat. So that'll do for today. Now for a late lunch and off to the pub!





Tim H.
1986 4/4 VVTi Sport, 2002 LR Defender, 2022 Mini Cooper SE
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Well done Tim!!

Looking good - awesome work!

Keep us posted on progress - but do not rush it!!


Neil

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It's a good colour match...........
Great work. If you were closer I'd come over and watch........ cozychair


DaveW
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Well done.


JohnV6
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Great work.


Richard
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Originally Posted By DaveW
It's a good colour match...........
Great work. If you were closer I'd come over and watch........ cozychair


laugh2

Me too

Great work Tim, looking good


2008 XXVII Platform, Bugatti Blue Roadster 4 Seater
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heart in mouth time with that cutter,I bet - but well done Tim thumbs .

The results are looking superb; that gel coat finish looks indistinguishable from the paint.... sherlock

Bye the bye, your earlier post spurred me on to look at the 10.8/12 volt Bosch angle grinder.Needless to say,'looking' turned into purchasing innocent

I have to say, it's one of the best tools I have acquired in a long while; it's been put to good use several times already.

Thanks for the tip - but please,no more 'till after Christmas;the piggy bank is feeling very light.... doh


James


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Hamwich Offline OP
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Originally Posted By James B W
your earlier post spurred me on to look at the 10.8/12 volt Bosch angle grinder.Needless to say,'looking' turned into purchasing innocent

I have to say, it's one of the best tools I have acquired in a long while; it's been put to good use several times already.


I'm glad you're happy with it, James. I have the hammer drill, impact driver, and jigsaw as well as the angle grinder so far. Lovely bits of kit.


Tim H.
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Good progress Tim.


Martin (Deano)
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