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Author Topic: Austin Ulster build  (Read 9113 times)

Steve Cole

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Austin Ulster build
« on: 04 January 2019, 10:54:46 pm »
This is my build. Started November2018. Loosely based on a 1927 Austin Ulster.
3Ēx 1Ē chassis then will be clad with plywood and fibreglass for the curved parts then painted.

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Steve Cole

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Re: Austin Ulster build
« Reply #1 on: 04 January 2019, 11:11:36 pm »
This the inspiration car...

RhysN

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Re: Austin Ulster build
« Reply #2 on: 05 January 2019, 11:03:31 am »
Hi Steve, that's the car I used as the inspiration for the "Great Austin 7 build off" which I participated in. The photo is after McLaren International re-restored it and took it to the polar opposite of what it had been when Bruce owned it. I have a lot of unpublished photos from the McLaren archives. It was NEVER pristine. Getting the scuttle humps right will say whether you achieved it. (Opinion only)
« Last Edit: 05 January 2019, 11:45:04 am by RhysN »

Steve Cole

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Re: Austin Ulster build
« Reply #3 on: 08 January 2019, 08:29:28 am »
This is the chassis upside down ready to weld up the bits I missed
« Last Edit: 11 January 2019, 11:11:52 pm by Steve Cole »

Steve Cole

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Re: Austin Ulster build
« Reply #4 on: 11 January 2019, 11:09:44 pm »
Chassis now welded up and I sprayed it black today.
Now to start on building the body 😊 [ Guests cannot view attachments ]

Steve Cole

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Re: Austin Ulster build
« Reply #5 on: 13 January 2019, 08:50:24 pm »
Iím now working on the body. Iíve mocked up the basic frame in 6mm mdf. Iím now. Carving the curved section in foam ( expanded polystyrene ) I build profiles in mdf then hot wire the foam to get the basic shape, then carve the curves wth wire brush and sandpaper. Next Iíll skin then make moulds in fibreglass

StefanN

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Re: Austin Ulster build
« Reply #6 on: 13 January 2019, 09:12:05 pm »
Nice work.   Would you be happy to share any more details about the how?

Is the back section made up of 3 sheets glued together?  How do you glue it?  Do you simply hot wire a straight line between the two profiles?  How do you use the wire brush?  ...so many questions!

Steve Cole

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Re: Austin Ulster build
« Reply #7 on: 13 January 2019, 10:38:09 pm »
Hi Stefan, this is kind of what I do a lot of the time for my business
Polystyrene... I buy blocks, 8í x 4í x 2í
I have a special hot wire transformer, special thin wire and a pair of cables
I make profiles, place them either side of the block and with someone to help me we cut one profile out
Then turn 90 degrees and cut the other profile
To be honest, you canít do this in your garage. You need space, a hot wire transformer and big blocks of foam
If I didnít have this Iíd do it the traditional way with profiles in mdf like building a boat hull and fill gaps in with foam or plaster
Hope that helps.
When we have a Builders day up here Iíll demonstrate for all
Steve

RhysN

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Re: Austin Ulster build
« Reply #8 on: 14 January 2019, 05:27:12 am »
I do exactly the same without a hotwire. Handsaw does the rough cuts just as well as long as you use foam with small bubbles. I use another chunk of the foam I cut off to "sand" the shapes. Surform or similar tool does a good shaping job, as does a bread knife, or electric bread knife. It's very easy DIY. No expensive gear needed. I did it for a living for some years.

Steve Cole

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Re: Austin Ulster build
« Reply #9 on: 18 January 2019, 11:19:41 pm »
Gel coat going onto the pattern for the back end ( or is that liquid chocolate 😳)
Prior to layers of fibreglass

Steve Cole

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Re: Austin Ulster build
« Reply #10 on: 20 January 2019, 10:40:52 pm »
Moulds now made and first cast of the back end out of the mould.
Plywood cut for sides
Iíll make bonnet and radiator casts next then start to assemble it [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ]

Steve Cole

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Re: Austin Ulster build
« Reply #11 on: 24 January 2019, 10:33:22 pm »
Iím starting to fit the fibreglass back end. I made up a bracket to hang it off. Now making the piece that goes above the seat fit as wel
« Last Edit: 24 January 2019, 10:35:49 pm by Steve Cole »

Steve Cole

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Re: Austin Ulster build
« Reply #12 on: 02 February 2019, 11:40:20 am »
My body is a combination of fibreglass for curved bits and 12mm ply for the flat sides
All screwed, gued and bonding pasted together with a few bits of softwood for joints
Now sand and blending it all together

241T

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Re: Austin Ulster build
« Reply #13 on: 02 February 2019, 06:13:43 pm »
bravo very nice work

Little French

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Re: Austin Ulster build
« Reply #14 on: 02 February 2019, 06:44:11 pm »
Good job !!
Aging is mandatory, growing up is optional .....