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This standard black XR3i is to be made into a cosworth
replica by fitting and painting the Autofashion Cosworth replica kit.
This is the same kit we supply to hundreds of customers around the
world, and provides a good insight into what is required to fit the kit,
and the likely final result.
Although the bulk of the kit is pretty much a bolt on simple job,
there is one job that takes a bit of time, and thats the arches. These
must be bonded on, and it takes quite a bit of time so sort these out. |
| Because this car is a "sound car" with plenty
of stereo we have taken the extra precaution of laminating the shell.
This involves stripping the paint, and putting fibreglass laminate on
the outside of the shell as in the picture on the right.
Once the fibreglass has cured we then bond the arch over the top.
In this way the panel is better insulated against the stereo
equipment that might otherwise crack the joint lines. This process takes
much more time, but is worth it for piece of mind. |
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The bonding process itself must be done quickly
because the bonding agent only allows a limited amount of time to bring
the two pieces together.
Firstly (above left) dry fit the items and drill all
mounting holes. Only when completely sure may you bond the arch.
Smear bonding paste on the car (above right) and on
the arch (left). Notice also expanding foam inside the arch during
assembly to improve durability, resistance to cracking and sound
deadening |
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Aligning and bonding the arch is a two person job
really, because of the time limitations. Once dry (at least the next
day), remove all external fixing screws, and sand the fibreglass and
surrounding metalwork very thoroughly - this is vital for adhesion of
the filler which is to be used to blend out the jointlines, and edges.
This is now a conventional bodyshop job. Fill, sand , prime, flat and
paint. |
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After the primer has cured, more hard work ensues.
The arches are sprayed with a coat of black as a "guide coat"
or "control coat".
This is then "flatted" back using 400 grit
wet'n'dry paper and a rubber block until all the black aerosol has
disapeared - this will go through to filler, fibreglass and metal in
some areas but if done properly will eliminate ripples, and other
defects to leave an ultra-flat finish.
After this stopper is used for minor pinholes and the
like and then the panels are primed again.
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