my bj 40 1978 resto

[totoy]

bj 40 1978 resto (make body alu by me)

Hello everyone

time flies, it is 4 years I worked on this project a little crazy to do the bodywork on this old toy.

this post is not a business, I actually just as passionate about these great machines.

to put it in context, I did my work, I bought my bj to 40 to 17 years under my apprenticeship. only my car that I drove every day knowing that I regularly pass through France.
in 7 years we go in Laval, anger, Bourg en Bresse, Paris, Tours, Lyon, Nantes, La Rochelle, Marseille, Bordeaux, everywhere.

I started disassembling January 2005

 

[totoy]

the toy was in relatively good condition does not really be replaced. but the urge to change my interest advantage over aluminum, and why not know if it would be possible to mass produce !!



harnesses
I wrote to the marker directly on electrical components.
this is can not be erased.

​

my body has special tools travel
a box for Tolerance
one for the mechanics
and one for power tools and other

​

[/LEFT]

 

[lostmarbles]

Wow. I'm going to enjoy this.

Looks like you've got my dream workshop there Totoy.

Am I right that you're planning on fabricating a replacement body from aluminium alloy panels that you're making yourself? (And these panels are available for sale to others.)

Cool!


Aha This thread answers a lot for me! Fabulous work!!!!......
https://forum.ih8mud.com/40-55-series-tech/87158-french-tubs-4.html

 

[totoy]

hello

Indeed, today I make the body in series
I prepare for a late 2010 ebay shop

I currently work exclusively for Europe

pictures of my bj 40 is the first aluminum body before my business

Here the following

disassemble cowl


disassemble the box



and all the rest

 

[totoy]

motivated the next day
I cleaning tricling all the chassis interior and exterior to the grindstone
(black shower insured:?)



this is not lose the rhythm applying the primer.
interior and exterior


then again in the rhythm under the epoxy
it to be fast because the day will end

 

[totoy]

Here is one of the most interesting part
order to build this fund in a very short time
So I began creating plans



I am creating a real working basis for a more abstract level it is a tool where I started the foundation and with whom I work today, and turns that I'm evolving.
approximately 250 hours to recreate the body on CAO DAO

 

[totoy]

Once the plan is I attack the flow of the sheet.

I mark each item on future tape because there more than 80 pieces to make.
whole body is on the wall, its been a strange feeling because it takes little space.
I always feel watching the plates I had forgotten a piece.



And here begins the plotting, ruler, set square, compass
and full of deletions because it is often forgotten a witch or we all simply wrong.

Then a cutting shears

 

[totoy]

attack the simplest pieces to bend.
crosses floor reinforcement ....



for the cross back, I realized a special bend, so that once set the floor and back through the same level.
the idea and crush the metal sheet between 2 others in a roller. (very old technique: wink.





and first places on the chassis (to see if all goes well)

 

[totoy]

ello everybody

here is the result.

I make panel by hand

 

[totoy]

I built low panel door

I make a solid and I hit with a hammer

 

[totoy]

first assembly and first control

 

[folsom50]

That's impressive.

 

[equus]

crap.. that is impressive..