ST Project update: roll your own(long with pics)
 

As I was prepping (yes still prepping) for paint (lots of sanding) I kept looking at the rear flares. Here are a few reference picts to help show what I am about to describe.

http://forums.pelicanparts.com/uploa...1059568943.jpg http://forums.pelicanparts.com/uploa...1059568964.jpg

The SC flares I used have a squared off lip to them. The more pictures I find of the factory ST's the less this squared off lip matches. If I were building an RS replica I would not worry about it. Herein lies the problem.

The front fenders have a very rounded lip to them. The car just did not look finished since the front and rear appear so different.

I just couldn't take it any longer. As they say its all in the details.

So I pull out the trusty hammer and dolly. HMM Looks like this dolly has a nice rounded profile on one side. Might even match the front fenders.

http://forums.pelicanparts.com/uploa...1059569176.jpg

Next step is to hold the dolly behind the fender lip and start shaping it with strategic hammer blows. The first step was to flatten the squared off lip with direct hammer blows to the dolly. This was then followed by pulling out the lower section using an off-dolly position.

The final results show that the fender is nicely rounded.

http://forums.pelicanparts.com/uploa...1059569322.jpg http://forums.pelicanparts.com/uploa...1059569334.jpg http://forums.pelicanparts.com/uploa...1059569527.jpg

As you can barely see in this pic, the rear has a similar profile compared to the front. I wish I could take better pictures. Yes, that coloring is the guide coat as I sand the car flat. Its nearly there.

http://forums.pelicanparts.com/uploa...1059569458.jpg http://forums.pelicanparts.com/uploa...1059569471.jpg

I have now taken care of my dislike for the fender shape. I have pulled/rolled out the fenders by about 1/2" and given them a new profile that matches the front. The car is really starting to take shape. I just need to finish the brackets to hold all my lights up front and I can get the tub painted.

Wow! Nice work Jamie!

Jamie,
Now it looks like an ST and not so much an RS. Nice Work!

Nice work Jamie!

Thanks for all the kind words. I have a vision of what I want the car to look like. Lots customizing is what it takes. Especially when working with fiberglass parts. Maybe that's why its taking so long to finish. Of course, the 2 hours it took to round these fenders and prime them is minuscule in the grand scheme of things. The rust repair was the greatest challenge.

Jamie,

Always impressed when someone can skillfully manipulate metal to their liking....as always, nice work.

I know you're probably sick of answering....but when do you think you'll get done!?!? That's gonna be one mean machine.

Charlie, The car was supposed to be out for paint by the end of July. Obviously I did not make it. It should be painted by the end of the month. The reassembly should be easy. There is much of this car that will not be going back on it. I would really like to make the Oct. DE in this car. Possible but unlikely.

Jamie, once your ST is painted, let me know if you'd like some additional help putting things back together. After all your hard work, you've got to get the ST on the road / track to start enjoying it.

I am impressed, that looks much better. And it only took 2 hours? Wow.

Did you have to use much filler?

I think its great that everyone thinks it looks better. Confirms my thoughts that it wasn't quite right with the other lips. Seems to be like the Hot Rod customizers. They say that its a good mod if you can't quite tell what was done, but that it looks that much better.

Chuck, There is ZERO filler on the lips. I managed to not have any hammer marks. I was using a large 1.5" flat faced hammer which left a nice smooth finish. I had one or two high spots that came out with an 80 grit sanding disc. I am sure I will find a few spots that need a smal bit of filler once I sand out the primer.

I admit that the 2 hours does not include the practice time on the cut out sections I saved from last year. It took a bit of fiddling to get a contour that I wanted.

Jim, I will call you and all the NoVA gang when its time to reasemble. Hopefully that will be around the first week of Sept. Extra hands are always helpful when bolting up the drivetrain.

Jamie -- You're an inspiration! (and inspired too!)

Jamie,
Looks great, I have the same problem w/my rsr, don't like the squared off look to flares. So now that you have practice....., I have inlaws in The DC area hopefully I can see car inperson at some point.
Phil

Thanks John,

Phil, Stop by any time. Was your RSR done with the turbo flares. They have a different shape than the true RSR flares.

Jamie

It's the cumulative effect of a hundred small decisions that brings a car's 'look' to life, in my opinon.

Great work!

Just wait until BB1's wheels are stuffed under there. I can't wait.

Jamie

good work. i'm impressed by anyone that can take a hammer to their car and IMPROVE it!!! I, on the otherhand, have a temporary restraining order against myself-Not allowed with 50 feet of my car with a hammer or wet/dry sandpaper!! max

I've never taken a hammer to my car, but a four foot pipe, yes!!, well no the P-car anyway.;)

Looks great, now I know there is a reason for them to be aloud to sell SC flares:)

wow....very nice! I wish I had the skills you have.

Have you decided on the color, or do we all get to vote ;) I like that early banana yellow color that I think some STs had.

I was going to do light yellow but have since changed my mind, which happens A LOT! (Just ask Dave or Tim) The color will be silver.

I am still on the fence about several aspects of my project. The most notable decision is to do a hood fill gas tank. Do I or Don't I? Every day is different. There are pros and cons for both.

Dennis, you'd be surprised how much help a 4' pipe can be. Hammers, on the other hand, must be yielded with car near the body, with wreckless abandon in other areas, like ball joint nuts. :)