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GAS FAB XM Coupe

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    #16
    Epic amount of work just to get the replacement panels up to scratch so you can start.

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      #17
      That is some very fine fabrication work.
      Norbie!

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        #18
        F5, F5 ,F5 ,F5 etc

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          #19
          Had a few other jobs taking effort away from the xm. Might be able to do a minor update tonight but would rather wait till I got the quarter back in.
          Customer Cars
          GAS FAB XM Coupe - PerformanceForums
          GAS FAB Mk1 Escort - PerformanceForums
          GAS FAB - 1985 Porsche 911 3.2ltr Carrera Cabriolet - PerformanceForums

          GAS FAB Cars
          GAS 260Z RB26DET
          GAS 1600 3SGE BEAMS

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            #20
            Ha thanks was only in jest

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              #21
              Very nice work !!!!

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                #22
                So, long time between drinks for this thread, but I wanted to wait untill the quarter (or is it half as it takes up half the car) was on before I updated again.

                Before I could get onto mounting the quarter panel, there was a few miscellaneous panels behind the quarter that had rusted away and required remaking.

                GAS_FAB_XM_Coupe_082 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_083 by GAS FAB, on Flickr


                I then welded them in.

                GAS_FAB_XM_Coupe_084 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_085 by GAS FAB, on Flickr


                The bottom of the B pillar was also looking pretty tired and rather thin, so I decided to make a replacement.

                GAS_FAB_XM_Coupe_086 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_087 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_088 by GAS FAB, on Flickr


                Finally, that brings us to the quarter/half skin. This panel had been on and off multiple dozen times in the last few months.
                This is what you get when you order a reproduction quarter, the main shape is in the panel but the rear of the panel is just straight, not return.

                GAS_FAB_XM_Coupe_089 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_090 by GAS FAB, on Flickr


                So that meant I needed to make a rear return, and the falcon has a great shape to it's rear quarter where the quarter folds under then does a sharp squarish channel up into the floor before dropping back down. That shape has to continue around and up the corner of the quarter and then flatten out into the rear bar. Sounds easy but took a fair bit of effort to replicate.

                Started with trimming and shrinking the panel around the corner.

                GAS_FAB_XM_Coupe_091 by GAS FAB, on Flickr

                Then I fabricated the channel in 2 sections and welded it in, sorry forgot to take progress photos.

                GAS_FAB_XM_Coupe_092 by GAS FAB, on Flickr


                Test fitted to the car you can see the elaborate shape in the second photo.

                GAS_FAB_XM_Coupe_093 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_094 by GAS FAB, on Flickr


                Looking at the panel door gap, I realised I was was going to need to spend some attention here to fix the gap. No progress photos here but there will be a final door gap photo.

                GAS_FAB_XM_Coupe_096 by GAS FAB, on Flickr


                Then it was time to get serious with this repair panel. Time to start cutting out bulk material.

                GAS_FAB_XM_Coupe_095 by GAS FAB, on Flickr


                Trimmed the qtr/half panel down

                GAS_FAB_XM_Coupe_097 by GAS FAB, on Flickr


                And made a matching cut out

                GAS_FAB_XM_Coupe_098 by GAS FAB, on Flickr


                Panel ready to weld in

                GAS_FAB_XM_Coupe_099 by GAS FAB, on Flickr


                This panel is the longest weld I've done on such a straight cut. It is also in a very low crown panel which has very little support which is just asking to distort when heated. I knew the panel was going to move on me, so I knew I'd spend more time planishing then welding.

                As I had some sort of access to the back of the panel (less then I originally thought) I decided to tig weld it in. Not many in progress shots as most of the time I was contortioned into tight spots trying to planish out the previous weld or holding tools in awkward positions to get to the back of a weld. I even asked the wife to help me out, which worked ok, but I decided to make a custom tool rather then try my luck too much.

                The back third and front third of the panel I was able to get very nice/straight. But I'm not going to lie, the middle third of this panel still has some distortion to it which I couldn't get out in the planishing done today.
                I also picked up some previous distortion in the panel from the previous repair that I had missed before welding in, so had to spend more time on repairing that then I expected.

                I'm sure with enough time it could be taken straight but at this stage I think a little filler will probably be ok. It will be a lot less then what came out of this side of the car to begin with that's for sure.

                GAS_FAB_XM_Coupe_0100 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_0101 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_0102 by GAS FAB, on Flickr

                GAS_FAB_XM_Coupe_0103 by GAS FAB, on Flickr


                And a finished shot of the door gap

                GAS_FAB_XM_Coupe_0104 by GAS FAB, on Flickr


                And finally a shot inside the quarter to show why I had created that chase in the sill panel. This gave a spot to be able to reach in with the welder.

                GAS_FAB_XM_Coupe_0105 by GAS FAB, on Flickr
                Last edited by garvice; 04-12-20, 11:23 PM.
                Customer Cars
                GAS FAB XM Coupe - PerformanceForums
                GAS FAB Mk1 Escort - PerformanceForums
                GAS FAB - 1985 Porsche 911 3.2ltr Carrera Cabriolet - PerformanceForums

                GAS FAB Cars
                GAS 260Z RB26DET
                GAS 1600 3SGE BEAMS

                Comment


                  #23
                  Very nice

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                    #24
                    Great work on the quarter!

                    Comment


                      #25
                      Woohoo.

                      Yes that's the thing with the replacement
                      panels just straight folds.

                      Comment


                        #26
                        Top work as always.
                        Norbie!

                        Comment


                          #27
                          Tidy!

                          Long curved panel with that much welding would be a mofo of a job to get right.
                          an easy fix is get a mate to drive in front of you at 60 then 80 then 100 and mark in on your speedo with some liquid paper.

                          Comment


                            #28
                            Cheers guys. It was a prick of a panel to keep straight. I still feel like I have a long long way to improve on my metal finishing skills if I want to get to the file finish type panels, but it all just takes practice/time.
                            Customer Cars
                            GAS FAB XM Coupe - PerformanceForums
                            GAS FAB Mk1 Escort - PerformanceForums
                            GAS FAB - 1985 Porsche 911 3.2ltr Carrera Cabriolet - PerformanceForums

                            GAS FAB Cars
                            GAS 260Z RB26DET
                            GAS 1600 3SGE BEAMS

                            Comment


                              #29
                              I just wish some if these so called high end tv shops in the US would see your work so they knew what real restoration is. Not their version if good enough and slap in the bog to get the shape.

                              As always, top work, and you make me feel like I have failed as a man......

                              Comment


                                #30
                                Here’s the thing. Not only is the workmanship is incredible, I have had similar progress reports every week. Brad, I really appreciate the effort it takes to not only do the stuff you bill for but also the detailed progress reports. I know it’s not what we were expecting but I am so happy you have taken it on as I know it has been done properly and will outlast me and prolly most of my sons ownership too!

                                many thanks mate!
                                "Beware the lollipop of mediocrity: lick it once and you'll suck forever" Brian Wilson

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