Projeky Hoopty photos -- 16 new ones

I don't have time right now to put captions on them, but it's been three non-stop days' work. Summary: new windshield broke. Everything else is right on time and the car's hotter than doughnut grease.
By the time Carlisle comes around next week, she'll LOOK ready to go, but I'll not be in running order.
Needs tins and plumbing, and still have to go through the motor.
Steering box made a big dent in my head yesterday as Jim and I tried to figure out how it and the fuel cell could occupy the same space. The steering won. We moved the battery, flipped the bracket for the fuel cell around and made a mount for the steering box.
AUUUGH!
Anyway, there are some very illustrative shots in there now of the detail work. And the hood pins are cool, too.

Wow! Just like mine, except for the 6,700 custom modifications. Very cool.

Yeap Cory, I am still stealing your ideas. Keep posting those pictures.

There are captions up now. I'm trying to be as descriptive as I can with them. Stay away from the 550 windshield idea until I get this sorted out; I'll be the Guinea pig on this one.
I called Dario yesterday to report failure, and I'll be on the phone again with him tomorrow about what to do next. It just couldn't take the strain of being flexed to the angle I flexed it to.
My fault, 100 percent, but I'm stuck on the idea that I can make this work.
That was the first thing to go wrong on the entire build. Everything else is just a matter of adjustment to fit or re-work to streamline. This thing is just flat broken.
Fooey!

Cory; since the crack is already there, try fusing it together with cyanoacrylic glue - very nasty stuff! It literally melts the plastic together. It's what they use for large aquariums. It might work better if you don't have stress on the material. The glue flows into cracks and will bond almost instantly. You can buff out the rest!

Ok, first the obvious.

Drill a small hole at the end of that crack to stop it from continuing. Use the cyanoacrylic glue as Mel said to seal it, and cover the crack with a secondary triangular aluminum plate. Then do a matching plate on the other side of the windshield. Make it look LeMans necessitated, race-ready and like it belongs there . . . maybe a small triangular computer generated sticker that reads "CAUTION: Stressed Area" to finish it off.

Now the IMPORTANT part.

I noticed that the floors haven't been installed as yet? Make the floor boards out of 0.5" Lexan so that you and your passengers can REALLY experience the thrill of an amusement park ride ! ! ! Kinda like being suspended in air while travelling past the double nickel. Don't laugh until you've tried it, it's a thrill and then some!

Looks WONDERFUL, I just LOVE the way that you think . . .

Luck!

TC

How small a hole? An eighth or three eighths of an inch?
I'm officially scared of that windscreen now.

Eighth inch would work, even smaller would do as well. Essentially the hole provides an end point for the crack; a circle being one of the strongest openings, the crack doesn't continue but spends it's energy at the open end point. No corners to focus the stress and continue cracking I guess.

MGB doors always crack just below the vent windows and we always had to drill a hole before welding the crack and then hole. It's a stress thing. I sure that somebody knows more about it.

I'll be doing that this week, then. Thanks, fellas.
I'm going to price Lexan for the floorboards, too. What a great idea. (May not happen, but it's worth mocking up to see how I feel about it.)

Holy crap! I LOVE the Lexan floor idea! Cory, you gotta try that. You realize, or course, that it'll be a bitch to keep clean. "Sorry guys, I can't go out for a beer with you. I have to Windex the underside of my car."

For the most part, you'll want to keep the lexan covered with simple floor mats. It's just TOO distracting seeing the road rushing beneath you. But for special occasions, especially a long caravan or if you have a co-pilot, remove the mats, crank the tunes and enjoy the rush.

I must have caught co-conspiritor Jim in a bad mood. He didn't even blink.
"No."
I'm going to make some anyway, since the floor's going to be flat and bolt-in. We'll call them "The Emperor's New Floorboards."

Cory, Lexan or Polycarbonate is prone to scratching. You will want to sandwich it with thin sheets of plexi to protect it from road debris and regular scuffing. It's a coooool idea....

Hey Cory!

If you drive around with the "Emperor's New Floorboards" installed, you'd be giving all the real estate you drive over the "Emperor's Snake Shot"! I'm guessing you'll understand this!

They're a great idea, but the girl says she'd never wear a skirt again. I'll come up with something. It's got me thinking again, though, about doing all the interior sheet panels out of Lexan or something ... You'd be able to see EVERYTHING when it's unfolded.
Except the girl.

Forget the lexan, just have expanded metal then you could feel the wind as well as see the road!!!!and because its a pleasure vehicle you could also BBQ on it:-)