Neil
Supporter
Slotted screws are an abomination! After a while, they get buggered up and usually have screwdriver blade marks along side.
Chuck's Jaguar D Type Build
- Thread starter CESLAW
- Start date
Thanks, Randy.
Yes, I should be using slotted, not Phillips. In visible locations, that is the plan. In this location, the screws won't be seen and are easier to work with. Of course, now that your sharp eye has noted that discrepancy, I may need to replace them!
Fuel Filler Door, Part III
The holes in the lower bracket that hold the mechanism are slightly oversized to allow adjustment of the roller grab latch mechanism's height and its position relative to the grab pin. A good alignment was easily achieved. It snaps in place securely, probably tighter than the original.
The original had a hole, about an inch in diameter, below the door opening that one would use to push the latch inward to open the fuel door. We decided to add this detail, but placed the opening on the door itself to make it easy to pull open. Hopefully, only the most fanatical D-Type purists will notice that the hole is in the wrong place.
We spent some time sanding the glass to work towards an even 1/8” gap around the door. Minimal filler will be needed when we start the serious body prep.
Next, we plan to sew the upholstery, which I suspect will take a while.
The holes in the lower bracket that hold the mechanism are slightly oversized to allow adjustment of the roller grab latch mechanism's height and its position relative to the grab pin. A good alignment was easily achieved. It snaps in place securely, probably tighter than the original.
The original had a hole, about an inch in diameter, below the door opening that one would use to push the latch inward to open the fuel door. We decided to add this detail, but placed the opening on the door itself to make it easy to pull open. Hopefully, only the most fanatical D-Type purists will notice that the hole is in the wrong place.
We spent some time sanding the glass to work towards an even 1/8” gap around the door. Minimal filler will be needed when we start the serious body prep.
Next, we plan to sew the upholstery, which I suspect will take a while.
Upholstery, Part I
Although Ryan and I have taken hundreds of photographs of original D-types, much about the seats remains difficult to figure out. Like the details of how the seats are designed.
Few of the original D-types in existence have original seats, and there is considerable variation in the replacement upholstery seen today. That means a prototype may exist somewhere for most any reasonable seat arrangement.
This picture captures the look we are seeking.
I have never sewn a single stitch, so learning to sew was the first order of business. There is an abundance of sewing videos, some good, others a waste of time. Between watching videos and making two, three, sometimes four, practice pieces, we gradually got the hang of sewing. Since this is a new endeavor for me, I welcome any advice.
I doubt anyone reading this will be fabricating their own seats, so the posts that follow will probably be a condensed summary of what will likely take many weeks.
Although Ryan and I have taken hundreds of photographs of original D-types, much about the seats remains difficult to figure out. Like the details of how the seats are designed.
Few of the original D-types in existence have original seats, and there is considerable variation in the replacement upholstery seen today. That means a prototype may exist somewhere for most any reasonable seat arrangement.
This picture captures the look we are seeking.
I have never sewn a single stitch, so learning to sew was the first order of business. There is an abundance of sewing videos, some good, others a waste of time. Between watching videos and making two, three, sometimes four, practice pieces, we gradually got the hang of sewing. Since this is a new endeavor for me, I welcome any advice.
I doubt anyone reading this will be fabricating their own seats, so the posts that follow will probably be a condensed summary of what will likely take many weeks.
Very Nice Chuck. I believe there were a couple of forum members in the UK that stitched their own seats. Hopefully they will read this and provide some input. Best of luck.
Regards Brian
Regards Brian
Ian Anderson
Lifetime Supporter
One member on here does this professionally…..on dentist chairs!
But he sold his Southern GT in the last while and not sure if he still checks in!
Ian
Upholstery, Part II
The first project was the seat bottoms. Construction of the seat frame was described in a series of posts long ago, so the current goal was to fabricate a cushion for those frames that would be comfortable and resemble the original's look.
A one-quarter-inch plywood base was cut to match the seat frame's dimensions. Polyurethane was applied to both sides. Slots were cut to connect the thigh cushion section to the frame on the driver’s side to maintain the shape.
Four T-nuts secure the plywood base to the seat frame.
One-inch-thick medium-firm foam was cut to shape. The thigh support was cut from one inch soft foam, shaped, and glued to the bottom foam with 3M 77 adhesive.
Making detailed patterns for the dark green vinyl was a slow, time-consuming process, but necessary because it had to be cut as precisely as possible. Once a design was determined and the patterns cut, the actual sewing could begin. Finally.
The first project was the seat bottoms. Construction of the seat frame was described in a series of posts long ago, so the current goal was to fabricate a cushion for those frames that would be comfortable and resemble the original's look.
A one-quarter-inch plywood base was cut to match the seat frame's dimensions. Polyurethane was applied to both sides. Slots were cut to connect the thigh cushion section to the frame on the driver’s side to maintain the shape.
Four T-nuts secure the plywood base to the seat frame.
One-inch-thick medium-firm foam was cut to shape. The thigh support was cut from one inch soft foam, shaped, and glued to the bottom foam with 3M 77 adhesive.
Making detailed patterns for the dark green vinyl was a slow, time-consuming process, but necessary because it had to be cut as precisely as possible. Once a design was determined and the patterns cut, the actual sewing could begin. Finally.
Upholstery, Part III
The passenger's bottom seat was completed first, since it is a simple flat panel. The driver's bottom seat, with multiple panels and a thigh bolster, was more challenging. Working slowly, it took a couple of days to cut the pieces and sew them together for each seat. The driver's seat is shown in these photos.
The foam was covered with a plastic trash bag to make it easier to fit the cover. The seat cover was stapled to the plywood base, which was then screwed to the seat frame with the T-nuts.
The cushions were set in the D and taken for an extended test sitting in the garage while making engine sounds. They are quite comfortable!
The back cushions are next.
The passenger's bottom seat was completed first, since it is a simple flat panel. The driver's bottom seat, with multiple panels and a thigh bolster, was more challenging. Working slowly, it took a couple of days to cut the pieces and sew them together for each seat. The driver's seat is shown in these photos.
The foam was covered with a plastic trash bag to make it easier to fit the cover. The seat cover was stapled to the plywood base, which was then screwed to the seat frame with the T-nuts.
The cushions were set in the D and taken for an extended test sitting in the garage while making engine sounds. They are quite comfortable!
The back cushions are next.
Thanks, Randy. This D-type project reminds me of the quip, "How do you eat an elephant?" Answer: "One spoonful at a time."
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