bb80sc/TRE/AutoInno project update

[opticalfuel]

Question: Is there a fundamental reason the large rectangle of metal is cut out of the original lid (other than obvious weight savings, and correctness re: factory method)

Can it be done without cutting out that metal? (seems like it would be stronger if you left it)

[opticalfuel]

Kevin,

How do you resolve the gap between the original decklid and the FG (middle where there is about a 1.5" separation)

I am eagerly awaiting your comments as I am in the midst of that step, and wondering how to proceed correctly.

Thanks!!

Logically it seems to me that the metal will be made to meet up with the FG, not the other way around.

BTW: It seems like I just discovered the answer to my previous question... the middle portion of the decklid MUST be removed or you simply cannot make the cross member of the original lid meet up with the FG.

(right?)

[Zeke]

I guess I'll chime back in since Kevin may be on a holiday. AFAIK, you have to remove the original metal skin wherever you plan on bonding the FG part to the underbracing. Your idea of a hybrid (metal around the grill and the rear portion in glass) may not have been attempted before. I mentioned this was going to be a lot of work.

But, to answer your question directly about removing a rectangular section of the original lid, I think you must. I wouldn't go about it any other way. The edges will otherwise just be too thick.

[opticalfuel]

Thanks Milt, (what is AFAIK?, sorry I am not up on all these acronyms)

I know I need to cut the metal and sand it down to the metal. I was just test fitting it.

I will also be thinning out the edges of the FG to fit.

The middle cross portion (bottom edge of the metal, where the grill normally attaches is the part that is making me scratch my head a bit.

Kevin didn't really get into how he proceeded to resolve that part of the decklid.

I guess if I prepare the decklid and ducktail - I'll have time to check back later and see the answer.

As you mentioned (and were correct) it's alot of work. I am planning to:

1. remove the decklid from the car, fix the left portion of the ducktail.. with FG, Carbon Fiber weave material. (have)
2. Strip the paint from the edges (leaving 2" around and 2" in the middle cross part and remove middle lower portion of metal)
3. Sand with 80 grit to create a good gripping surface for the FG
4. Finish prepping the FG for attachment
5. Test fit, fine tune
6. Look for any new notes on PP (from you or Kevin)
7. Start mixing and clamping once I better understand what to do with the middle portion.

Is the correct thing to leave the surrounding metal for the grill and remove the FG (rear, lower portion) of that and Glass it in smooth?

I'll try to sketch something to demonstrate what I mean soon.

[opticalfuel]

Ok.... Go ahead and look back on the following post... Updated pictures

Duck Tail Cut-N-Paste?

Completed:

1. Stripped paint
2. Sanded to clean metal with #80
3. Cleaned up FG (ready for mount, after left top fix)
4. Posted pictures of progress.

Cheers!

[opticalfuel]

More progress:

Carbon Fiber reinforcement added to broken area... to mend break. Letting that set for 12 hrs or more... then setting up for duck tail skin graph.

See above thread for pictures!

[Jagshund]

AFAIK= As far as I know
IMHO= In my humble opinion
IMO= In my opinion
FWIW= For what it's worth

[opticalfuel]

More Fabrication updates ... see photos.

Created a new flange in Alum angle, riveted to the orig lid, shaped to fill gap between orig lid and new Duck FG.

Doing final fitment and bonding this week as time allows. Stay tuned.