Oldcarnut's Superbird Clone

[oldcarnut]

Thanks Nascar. 
After I got the buckets together and bolted in the nose I worked on the Z Brackets and the fit in the nose support brackets.  There was a lot of room for error to get the alignment off which would affect the other pieces attaching to them also.  The Z brackets had marked places to cut slots and holes in them but the nose support brackets didn't have any which left me wondering just where or how far in to put place the brackets and the corresponding bolts holes.  Mike (Dayclona) advised to make sure I left a gap between the top of the Z and the nosecone surface so that any future heat warpage or shrinking wouldn't distort the cone surface.  He also hooked me up with the special thin head bolts  I'm glad he mentioned that because I hadn't thought about it occurring.  I used some thick cardboard and foam rubber to maintain a gap.  Long story short of trial and error, I ended up cutting and attaching the rest of the parts (latch tray and metal frame brackets) all together with the cone for a mock fit.  After I thought it looked about right and with clearance, I drilled the lower support locations. 

[oldcarnut]

The first real assembly issue I ran into was that the Z Brackets did not fit flush against both the lower supports and the bucket sides.  I had a big ¼" gap between the Z side and lower support which would have caused twisting or stressing if bolted up tight.  One side was off more than the other.  It wasn't anything I had done but the location of the lower support was not in the right place.  I think with the glass parts thickness stacking up and not being compensated for, it moves where the sides end up verses where it would be with stock thinner sheet metal.  Other cloners mentioned they had this same problem with their fiberglass noses.  A couple pics of the gaps.  1st pic shows one side gap.  2nd & 3rd shows the shims I made to make it even and use for extra supports to put on both sides of the brackets to stiffen things up and support.  I did this to both sides and it made a big difference. 
   

[oldcarnut]

Nest thing I did to the Z Brackets for some strengthening was add some about 1/16 "stainless sheet metal to the insides.  Also another view of the lower support bracing.  

[oldcarnut]

Well with everything bolted up and aligned, it was time to figure out the light movement.  A friend of mine gave me an electric motor from an 86 Porsche 944.  They used only one motor for both lights and also had springs on the linkages to overcome so I figured it would be plenty strong enough to work mine especially with the leverage I built in and no springs.  I fabbed up the linkages I needed to join both together and made adjustments to get the stop positions good.  The motor stops are set in the motor and nonadjustable so I had to build the linkages to do it.  The motor also has a knob on the back for manual operation.  I just got to find where I set it down.  I'll access it through the bottom sheet metal if it fails one day.  Here's a few pics of the linkage.  Tested it out and it works great.  Hopefully this weekend I can the light harness extension done and motor wired in to work off the switch.  I posted this video on another thread but will have a better one when completed.  Give it about 10secs to start showing the motor working
http://www.youtube.com/watch?v=GkabXG8tDlQ
 

[tan top]

clever idea  nice work  

[nascarxx29]

 

[moparstuart]

    very nice work

[Charger-Bodie]

I really like the way you did the headlight motor...... Very smoooth operation. If I hadnt already set mine up for the factory stuff I would have likely been bugging you for stuff to do it that way.  Great job!

[oldcarnut]

Thanks all! Best benefit was since I made my own parts that the whole setup was cost free made from scrapped alum,  donated rod ends and motor    I just hope it ends up working out on the long haul but I see no reason for it not too.

[billssuperbird]

 

[BigBlockSam]

i've seen other electric lights  but yours seem to go up and down effortlessly 

[Old Moparz]

Dave, they work great, nice job.   

[randr]

Im doing this can i copy ya?

[oldcarnut]

Im doing this can i copy ya?

Sure why not    Thats part of the benefit of sharing ideas.  Have any detail questions feel free to send me a pm
David

[dreamcatcher]

Wow with all olur clones out there..pretty soon there will be more S birds than mustangs 

[moparstuart]

Wow with all olur clones out there..pretty soon there will be more S birds than mustangs 

[oldcarnut]

Its been about 4 months since I last posted so a little progress report.  Unfortunately it's just that-a little-as not much time has been available to do any work on it.  My engine machine work has been completed and 90% of the parts delivered.  My restored 6 pack carbs should be arriving in the next week or so and Jamey (RD) is finishing up my tranny.  The Ebay fender I bought from someone in Ohio hopefully will be here in a few weeks when they come down for vacation at Hilton Head. I started fabbing up my stainless dash and nose trim.  Posted the rough cut 11g. (1/8") pics so I could show a before and after when it's done.  I have almost finished the glove box piece but it's currently on a trip to hopefully get autographed  .  After a seemingly long wait it seems like things are slowly coming back together around the same time. I started selling off some extra and non needed stuff on Ebay to generate some funding and made a good score on an old Cobra Accelerometer I had since a teen.  Gonna post some wants for some more items I need and trades shortly in the classifieds like the new 69 dash pieces I can't use, a set of dog dishes, and some other things.  My directions with this project has turned and twisted in its creation as I go so I guess I will not be able to call it a clone but maybe a custom tribute

[pettybird]

it's like 10 degrees here and we're covered in snow, but if someone wants the wiper motor out of my 944 parts car they can have it for shipping cost (like $12).  Just don't expect it anytime in the next week or two.

[pettybird]

waitaminute... it's FREE but you have to fetch it at my national meet!   

[oldcarnut]

it's like 10 degrees here and we're covered in snow, but if someone wants the wiper motor out of my 944 parts car they can have it for shipping cost (like $12).  Just don't expect it anytime in the next week or two.

Did you mean the headlights motor when you said wiper motor?  Today we had 76* and it was nice outside  .  Tomorrow its back to the 30 and 40's  .

[moparstuart]

waitaminute... it's FREE but you have to fetch it at my national meet!   

I'll pick it up with my polara hub caps

[oldcarnut]

Getting a little more done on the dash piece.  Still collecting parts for the engine build.  I've gone way past on my motor budget what I intended to do so I hope it turns out worth it.

[Old Moparz]

I really like the stainless dash, it came out nice. 

Not trying to derail the thread, but a while back I had a bunch of issues with a GE refrigerator. It's one of the barn door models with the freezer on the bottom, & it's stainless. I had door alignment problems that was finally resolved by GE sending me doors & doors, & more doors, until a set finally fit. They didn't want the old doors back, so now I have like 6 extra doors.

I'm trying to remove the flat stainless face from the rest of the door without damage to salvage the large sheet to do the same thing, make a dash trim set. 

If the one door is enough to make a dash set, & I don't ruin it, I'll be willing to send whoever else wants a door for just the shipping fees. It's already packed in a cardboard box. 

[oldcarnut]

I still have some surface finish sanding to do on it after I drill some more holes for the gage programmers, indicator lights, and countersinking the mount holes.  I'm glad I bought the special clear coat paint to put on it as it will show up finger prints if I don't.  The panel is 1/8" thick so I could weld on the backside parts.  I had it cut out on a waterjet machine so if something ever happens to it at least I can get them to pop out another.  Its amazing how fast them machines slice through it like butter. I have a lot of 304 stainless sheetmetal in the garage that I got for super cheap so that's why a lot of my misc. stuff is made from it instead of regular steel. My glove box piece is still out on the road to be signed.  The radio plate will have to be done after I figure what kind of radio I buy for it.  I had to send my piston rods back for reworking the resizing on them.  Before he presses them on the new pistons again I told him I want to send the rotating assy off to be balanced.  My goal this weekend is to get the dash plate finished, cam brgs pressed in the block, and get a wish list inventory on what else I need to buy to complete the engine build.  First weekend in a while to be able to work on anything.

[oldcarnut]

In for a trial fit and slipped right in after cuting in the bottom center steering wheel clearance.