Scuttle wrapping

[Steve Bryant]

The one operation of my 1929 AD Van body build that has me intimidated and apprehensive to some degree is the wrapping of the scuttle in sheet aluminum. John Heath’s Instructions are rather simplistic:  “make and fit scuttle panel. Ensure pillars don’t move when wrapping panel”

Since I’ve never wrapped a scuttle before, I am appealing to those of you who have had some experience in this procedure to share your observations and experience with this if you’d be so kind.

I’d like to do this with one piece of sheet if I can and I have a pretty good idea of what is required, but I would dearly like to find out how to reduce the issues that might arise from doing it this way.

I am lucky to have the use of an English Wheel and a bead roller, along with a good selection of hand tools for panel beating so I am not wanting in that department.

I have even considered making the aluminum scuttle in three pieces and having them welded along the right angle bend from the windscreen pillar to the radiator shell, or the same thing only in 20 g steel which I can gas weld the seams on.

What are your thoughts on this ?
Your input would be greatly appreciated.

Thanks,
Stephen
Stephen

[kenkimber]

   

Steve, 
   When I constructed my Roll Top Newspaper delivery van, based on just two original photographs, I was faced with exactly the problem you describe.
   Although my scuttle is not the same as an AD it is very similar.
   As I have only basic hand tools and no welder I adopted a pragmatic bodge approach, which may not be approved of by the purists - but it worked !
  I made a join along each shoulder by using a joggler then overlapping the aluminium sheets which were were then fixed to the wooden frame with small countersunk brass screws. 
  After careful filling and rubbing done I was happy with the result and as the attached photograph taken a few months ago, shows even though the van was completed a few years ago the Join is still invisible.

[Ivor Hawkins]

When I built the “Chummystein” which was an AF replica on a long wheelbase chassis, I made the scuttle in one piece of half hard aluminium.

By cutting a cardboard template I as able to wrap the template over the scuttle frame and bulkhead to ensure a perfect fit over the scuttle, the bulkhead and down the sides where the bonnet sides fit and what is essentially the A pillar, where the door hinges are attached. 

After trial fitting of the template, I cut the entire panel in one piece and wrapped the entire scuttle without annealing, wheeling or the assistance of a rubber mallet.

I temporarily pinned and clamped the panel on the centreline of the scuttle where the windscreen sits, wrapped the panel over the scuttle so the corners above the A pillar were in line, then clamped the panel to the centreline of the scuttle above the tank, then down the sides, making minor adjustments before riveting the panel starting at the top and working down the sides.

The long wheelbase lines didn’t appeal to everyone (it was only a bit of fun and at least saved another chassis) but the all aluminium and steel body came out very well, I think.

   

[Steve Bryant]

Wonderful guys...thank you for the response.
Stephen

[Duncan Grimmond]

As has been suggested make a card template for the panel, ensure it is as precise and accurate as possible. Mark the extent of the curved section as accurately as possible. If you have sheet rolls it will be much easier, it might be worth cultivating your friendly local sheetmetal worker (if available) for the curved part. I use card of a similar weight to cereal boxes, infinitely better than corrugated which has “grain”. It might be easier to make three separate parts in card to ensure you have the curved part bang on and hang the flat panels to it with masking tape.

[Peter Naulls]

It all depends how authentic you want it to be. I believe the originals were fabricated from 3 pieces welded together; the "corner" of the scuttle is concave and can't be replicated from a single sheet. Having said that there are some lovely replicas around that ignore that fact!


  Austin Van.jpg (Size: 59.79 KB / Downloads: 265)

[austin]

I've got an unpainted John Heath chummy body with a scoop scuttle. It's in storage but if I get a chance I can take some photos.

[Steve Bryant]

Great stuff to know. I wonder if there are any factory pics that would show them wrapping the body ?

I would think that a one piece wrap would not be an economical use of sheet aluminum in the factories scheme of things and would think that perhaps the three piece welded one would make better use of the sheets with less wastage as the various parts could be oriented on the sheet to make the best use of it all.
Is there a way to confirm the welded three piece wrap?

Stephen

[Steve Bryant]

After discussion on the issue with my colleagues at work we tend to think that a three piece aluminum scuttle welded along the bend from the top of the A pillar to the bulkhead might be the best option. The pieces would be easier to make and control with the welding being the final step in making the scuttle wrap whole. Consultation with a specialist aluminum welder we use tends to think so too.

Any thoughts on this ?
Stephen

[Henry Harris]

I took this pic last night outside the pub.
It is looking up under the scuttle of EA tourer, B 511, a very well used, un-rebuilt car.
To the left is the rear corner of the NS glove box and to the right is the firewall. Across the top can be seen the back of a long weld.