Long day on the nose

Saturday was another "long" day. Long in that I was able to work on the E9 for more than three hours. Like the week before, I got a lot done even though it does not look like it.

The first thing to do was to sand off the last coat of primer applied the week before. I noticed a little breakup last week but it was more extensive after thorough drying.

As I worked the RH side I spotted a small high spot. Strange that I didn't see it before. I suppose that explains why the PO put so much bondo on the fender. I was surprised to discover that the area was lead, thick enough to file down most of the high spot. Working lead is so easy.

Over on the LH side I found a low spot just above the side marker light. It turned out to be a high spot a little further back, where the concave curve below the trim line blends into the front of the fender, all convex curves. I considered taking a hammer to it but was afraid of distorting the marker light opening. Besides, it is not all that visible. I decided to do what the PO did, use a little filler to fix the blend.

I did some more work along the bottom of the grill opening, especially where it meets the air dam, and around the bottom of the center opening. Slow going due to the bumper bracket.

The last thing I did was open up the rusted spot at the back of the hood opening, while thinking about how to repair it. I was going to weld it, but access to the back is blocked by the inner fender, and the curves are wicked. Besides, this is not structural. I think the best solution will be two layers of fiberglass cloth; I just need to figure out how to mold it. Note to self: buy a new set of rotory files, because the shop's are shot.

The last last thing I did was shoot all the bare places with etching primer. A thin coat, no dry mud effect.

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Still on the nose, regret the loss of Redline

Took Friday off and spent much of it on the E9. Stopped off at what used to be Redline in Kalihi for a wedge shaped sanding block and some wet paper. The paint section looked worse than ever, and still no new Redline oil. I asked about the block and was told to try the "paint center" in Pearl City. Since I had the whole day I decided to undertake the adventure.

Turns out Redline is no more, bought out by NAPA. The paint center does have PPG paint, but the situation with my sanding block is cause for concern. I was told that since it is not a NAPA item it would be 6-8 weeks before it came in, if ever. So what used to be the only professional automotive paint store in Honolulu is now just another NAPA. What a shame. On balance, NAPA is the only store I trust with repair components for average cars, like my van -- water pumps and such. The others sell nothing but junk. For me it is factory original, or NAPA. Anything else is a waste of time. For specialized cars like my E9 and my Lotus there are reputable sources, just nowhere near Honolulu.

Just for fun I decided to locate the new store on Google Maps. Check the comments ... my feelings exactly. The exact opposite of the old Redline.

My Saturday session was longer due to no Gamelan rehearsal. Over the two days I got a lot done, but not much "visual progress." Sanding, a little more filler, another coat of primer. Tweaks everywhere. One place that is taking a lot of time is the area below the grill opening on the LH side. Trying to even out some old impact damage and deal with the acute angle at the joint with the air dam.

Exposed a new spot under the LH side light. Not rusted, just pitted, like old damage. Wire brushed, POR-15 clean and prep, filled with Technifill.

One new thing I did was to start grinding out some rusty spots in the underside of the hood and near the windshield opening. Nothing big. Looks like I'll have to weld a patch along the corner of the water gutter, just like the rear trunk opening. Gave all of the exposed areas the POR-15 clean and prep treatment.

I exchanged mail with Coupe King concerning door skins. Apparently he has steel for one side and aluminum (CSL style) for the other. Guess I'll keep looking. I'd like to add one of his air dams, but I'm sure I'd knock it off at the first parking lot.

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Nose - all that's left is tweaking

After a little look-over and fine sanding, the first thing I did today was add some TECHNIFILL to the low spots. Well, actually, the first thing I did was apply Metal Prep too all the bare places, because in just one week of rainy weather, surface rust had set it. In Hawaii you just can't leave steel unprotected for long.

While waiting for the filler to set I removed the two grills from the hood. This was easier than expected because the screws go into plastic. For the car to look good these will need to be replaced. I wonder how other E9 owners deal with this.

When the filler was set I did a lot of sanding, trying to blend the new stuff with the surrounding surface. I actually started using 100# paper. I added the radius at the top edge of the roundel mount using a spongy sanding block. I removed the jig and smoothed the filler even though it will be hidden, mostly to ensure good water drainage. When everything was good I shot it all with POR-15 Etching Primer. I used this instead of the 3M product because of the fiberglass patches applied with POR-15. As it turned out, two of those patches had pin holes. I tried smoothing the paint with a fingertip the fill the holes, but of course the surface ended up a mess.

The last thing I did was add some filler on the lower LH side and the upper RH side.

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Fathers Day Ride

I usually think of a ride as a group activity. The annual Toys for Tots motorcycle ride, or the HBL Honolulu Century Ride for bicycles. If I waited for such a ride to take out my Lotus I doubt it would ever move.

Today is a beautiful day, and I decided as soon as I got up to take the Lotus out for a spin. I had to clean it up a little, mostly the wheels and windshield, then we were off on a south shore loop. "We" being me and the car.

I pulled over in Hawaii Kai to take some pictures. As soon as I got out of the car I was set upon by a delightful family; mom, dad, son and grandfather. Obviously out to celebrate Fathers Day. I said hi, and the questions began.

"What kind of car is that?"

"A Lotus? What year?"

"Is that the first model?"

"Why does it have two gas fillers?"

"What kind of engine does it have?"

"That must be the only one in Hawaii."

"What is it made of?"

I love it when that happens. Total strangers see my car and feel compelled to react. They wave. They honk. Or, like today, they overcome their deeply ingrained conditioning to mind their own business.

I sure hope that family will remember this Fathers Day as the time they saw that little yellow car.

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Roundel mount looking good

There are few things more satisfying for a mechanic than the first time an engine starts. We had one of those today, a Subaru in for an engine swap, all shiny and tricked out. The happiness on that guy's face was unmistakable. Every long term project needs some milestones like that. Otherwise, it just turns into an endless grind. I know I'll celebrate the first time I shoot my E9 with primer, in the paint booth. Maybe I should not wait so long. Like, when the nose is finished.

Every Saturday I inch a little closer. Today was all about shaping the Epoxy Filler I applied last week. As expected, it was easy due to the filler being rough shaped when applied.

As the first round of roundel shaping progressed I could see where I had a few low spots. Being minor imperfections, and not wanting to wait another week, I applied some TECHNIFILL. I also applied a bit more along the top, above the roundel, where it seemed necessary to flow into the sheet metal on either side. While that set I worked on the top on the RH side, and along the bottom of the LH grill.

When the TECHNIFILL was set I used my tool again to sand it smooth, and the long blocks to blend in the top surface. There is a bit more shaping to do, so I did not add any more filler. I took these pictures at the end of today's session. The first three are without flash, so that the shadows highlight the shape. The last three are with flash.

For comparison:

Before work began:

After initial stripping:

Reconstruction:

Seeing these photos all in one place really brings home how much work has gone into this.

Roundel mount shaping tool

For a long time I planned to shape the circular, recessed roundel mount with a self made tool. During that time the design changed several times. Today I made the tool, so it was time for all the alternative universes to collapse.

I knew I needed a tight grained wood ... plain old pine from a 2x4 just wouldn't. I ended up buying a piece of Popular from Home Depot. A bit expensive, more than what I usually spend on lunch, but a nice piece of wood and mostly left over for future projects.

I decided to use the wood on edge. After cutting out the piece of wood I needed I had to drill a hole for a 0.25 in. pin, which will keep the tool centered. My new Craftsmen drill was perfect for this (okay, a good drill press would have been better but I don't have one) because it has a spirit level in the handdle. Thank the bathroom renovation project for the new drill. I clamped the wood in the vise, clean length-wise edge up, leveled it, then drilled successively bigger holes which keeping the bubbled centered in its circle. I stopped one size short of 0.25 but the fit was so tight I was afraid I would split the wood, but after drilling out with a 0.25 bit the pin was not as tight as I wanted. Oh well.

The block rotates around like the hand of a clock. I had to cut away most of the underside to clear the steel plate and bolts that go through the holes used to mount the roundel. The last step was to shape the working end to for the curve that will creat the radius at the edge of the recess. File and check, file and check. You can remove wodd, but you can't add more.

When at last it was done I used it so sand off the filler that already extended too far into the mount. More than half would need more. I sanded off the primer and was applying a new batch of POR Epoxy Putty when I was struck by an inspiration. I could use the tool to mold the fresh putty. Worked like a charm. There will still be some sanding, but I will be starting much closer to the end point.

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Nose and Grill

I examined the contours on the nose and found some slight undulations on the RH side. Sanded a lot with 40# on the long and short blocks down to bare metal on the high spots. Checked fit of bright work trim piece. Added more Technifill.

While filler was setting I worked on the roundel mount tool. Found a long 0.25 in. bolt. Cut off head, filed end flat and smooth. Looked around for some wood, nothing useful.

After another round of sanding there were a couple small low spots so I applied another small bit of filler.

Ended the morning working on the fit of thee grill. More to do there.

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