Back hatch

[CarlB]

I got a new roll cage two years ago and the tubes that come off the top bar and extend back do not attach in the normal place. I looked around for an upholstery shop to make a new one and they were all busy. I wanted to use the car, so my wife, who is a real good sewer, and I made one. I wasn't happy with the results and decided to make one in metal. I am almost happy with the results. I have some mistakes you will see, but I learned a lot making this. There is nothing square on the car. You have to learn how to fit templets to one section at a time. and piece the templets together. This is very time consuming, and I cut up a lot of cardboard, but I am happy with the results, and it fits reasonably well. I also figured out how to use a bead roller to make a flange on the two side pieces for the hatch to lay in. Because I wanted a rolled edge on the corner pieces you need to stretch the metal to make the piece lay flat. I had not anticipated that and had to figure it out. I rolled the edges with a hammer and the side pieces are made out of aluminum that is not tempered, so I was able to eliminate the bumps with small taps with a body hammer and finish with a file.  The hatch is tempered to make it stiff. When I rolled that edge, I could not get all the bumps out. I intended to paint the parts, so I used a little body filler to even everything out. I used Eastwoods 2K primer and that is a really good product, but I couldn't get a good finish on the parts with the paint I normally use on my roll cage. I was using spray cans and everything I was doing failed. I took the parts to the powder coater, and he got a nice finish. Unfortunately, I have bumps in the rolled edge of the hatch. The big mistake is not knowing how to buck rivets. I have a piano hinge on the hatch and you can't use pop rivets or the hinge will not lay flat. I hadn't used solid rivets before and should have practiced more. It isn't hard to use them, but you can't put the bucking bar on the table. You have to hold the bucking bar in one hand and the rivet gun in the other, or you will wind up with the mess you see in the picture. The blows from the air hammer are too violent and you can't control it. You have to enjoy working on cars or fabricating to do this. I find it rewarding and enjoyed the process even though I made some mistakes I gained some skill. I am stuck in the house, so I did this post. The first picture shows the almost finished cover. The latches are not installed. It you look closely you can see where they will be. I will post a finished picture later.   

 

 

 

 

 

 

 

 

 

[fastg]

Carl, where did you get that idea?

 

Graham 

[CarlB]

Exactly where I got it. I looked around at some different ones and I liked yours the best. My side pieces were harder to make because the Caterham slopes down slightly after the down tube for the roll bar.