Suzuki Club UK

My current time in lockdown has been a constant struggle between being as constructive as possible, and giving into total laziness. Its reminded me I really am quite lazy, but I've been trying to keep the balance.

All of the work I have done has revolved around the front wings, and getting the front end to line up nicely. These new wings are a massive advantage over the old ones, but still needed some fettling. Somehow the spot welds between the outer wings had pulled apart or swollen up and then just been body filleted over. These are supposed to be a nice tight seem, so I ran a cutting disc down them, drilled them and puddle welded them back together. There was a big chunk missing from the bottom of the grill panel, so it wasn't sitting properly to test fit the wings. I rebuilt it by mirroring the other side which fortunately was still there. The other side is rotten though and still needs to be replaced. Next up, the N/S Wing overhung the grill by about 5mm. I was quite happy that the grill panel was perfectly symmetrical because I measured it 100 times when I welded it together. I solved this by drilling the spot welds on the inner wing, pulling it over and welding it back together. It looked like somebody had already done this on the other side and it didn't have the same problem.

The radius on the front corner of the O/S wing was to tight, so didn't marry up properly with the grill panel and didn't match anywhere else. It had some previous rough repairs. So I cut it back quite far to where the edge had a better radius and made a new panel. With these parts corrected I could make the brackets to hold the wings to the grill. I chose the dimensions based on little rusty bits that where left of the old ones and from a few pictures I'd seen.

The two upstand brackets that hold the wings to the bulk head had been cut in half and half of each was missing for some reason. I assume they had rotten off at some point. So I made these based on one or two pictures I found. So I think they are close to being right. This recess where the wing sits in was a million miles too far forward to start with. This obviously wasn't a problem for whoever welded it together previously because they never fitted any proper wings. So I cut it back and boxed it in to match the curve of the new wing. But after doing this I've started to think that I have cut it back too far based on one original bolt hole that is left, and how the other side sits. The back of the wing on the other side sits too far forwards. I have a feeling neither of the wings are the correct shape around this part, and it will need further addressing/reworking. So that will be the next thing for me to attempt. I might just repeat the same on the other side to match.

Brilliant work! Loving it, now that's how I'd like to be spending my time!

I haven't updated this for aages, but don't fear as I still have the LJ and have still been making progress (very, very slow progress)

I was all geared up to repair and make good of the (incorrect) rear quarters, until I started pulling tons of body filler from them and then lost faith. So I changed tact, bit the bullet and ordered two new panels.
(check out that deep valley of body filler)
These weren't cheap and absolutely broke the bank, so every other panel I need around them I will be making myself.
Once this side is made and tacked in place I will start on the other side and try to coppy closely.

Brilliant work!

Thanks Anton! I appreciate the apretiation

Eljeeholland want €250 for the little rear corner piece, so tonight's task was to have a bash at making one.

Very nice work indeed!

Looks like some awesome fabrication work going on.

What a joy to see, the trouble with flipping through a few posts on a computer you do not get the true feeling of the effort of what you are achieving here. It is just fantastic to see and thank you for sharing it, what a brilliant, highly time consuming job you are doing.