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Thread: My countach build (dial up beware)!!!

  1. #1
    Junior Member turbo355's Avatar
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    My countach build (dial up beware)!!!

    Hello i dont post on here much mostly just read and look around.

    I thought i would post up some pics of my car this is posted on another site so some of its is over a year old now.

    My car has been setting for around 2 years now waiting for me to get the energy to tackle replacing the doors, they are around 12 years old now and are really starting to show their age, i have a brand new set of fiberglass doors for it but i decided if im going to be messing with the doors, why not start from scratch.

    This was my car before i started on the pass. door .





    The doors have always leaked around the tops,, and i could never keep the side glass from breaking eventually, since the top frame was so weak . So i started with a sheet of .063 aluminum , and started building, i have about 20 hours in this door so far including the window regulator stuff, witch still need some work but it seems to be going good so far. ( please forgive the bad pics i will shoot some better pics )








    The window regulator is out of a 95 (or so) Ford escort it is cable drive setup ( real simple and free ) So i started and made a stell bracket out of 3/16 plate and turned out some pully wheels for the cable to ride on i also made up a bracket for the window to set in out of .090 aluminum that the cables also hook to this will be urathaned to the window to push and pull the window up and down in the track , i made an adjustable to take the slack out of the cables for adjustment .








    As you can see i put the window bracket at the front of the window as this seemed to work the best for working the window, if it was to far back it would pull the window out of the channel here it seems to work real good.





    Here is a shot from the front, i wanted to stay as close to the orignal design for the doors , so all the window channels are welded to the door itsself , and the wing glass divider bar has the inside support just like the real countach, this helps to hold the corner of the top of the door down on the seal without any movement .





    And here is the front of the door where the wing glass slides up into this will have felt strip inside so once the wing glass is slid into the pocket it will be sealed from the outside.






    Thats all for now i will take some pics of the inside of the door when i pull it off the car , i still need to add a window bracket to the back of the glass with a cable going to the front to make sure the back cant slide up out of the channel once that is done then i can skin the door and start on the drivers side.

    I know it looks like alot of work to buld a door out of aluminum but i just dont like the fiberglass doors for these cars ( or atleast the ones i have) i weld aluminum almost everyday here at the shop so it seemed like a good project and so far im happy with the outcome we will see once i start to skin it if i still think it was a good idea. LOL
    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  2. #2
    Junior Member turbo355's Avatar
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    Re: My countach build

    Here are some shots of the inside of the door, it still needs alot of finish work, but the over all shape, and fit is correct so far. Also note the inner door frame itself, is seperate from the outside of the door frame, so basically its like having a frame .128 thick, but since its two pieces, and it has 90 degree bends in it, it is stronger than a single piece.















    Here is a shot of the inside wing glass support bar this runs from the top of the door frame to the 1x1 bar at the bottom it is made out of .080 thick sheet bent into a u section then welded the whole lenght of the window channel





    Here is some shots of the pulley wheel setup im using , the front has 4 wheels, 2 are for the actual drive setup, and the other two are for the back of the glass, a cable runs fron the front glass tab to the back of the glass through 2 more pulleys, this keeps the glass from sliding out of the track in the back plus helps to pull the glass down . Im still unsure if this is the final setup i will be using so untill i know for sure i will wait till i do the drivers door to show the cables in place.










    Here is the start of the skin, the top has returns for both the front wing glass, and the back lower glass, so felting goes on, then the glass can be installed ,and a final trim piece will go on just like the original doors, this should make for a water tight seal to the windows from the outside ( hopefully) . I still have more welding to do to the top skin, then i have to file and sand it all down, then i can start on the main side skin and scoop.





    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  3. #3
    Junior Member turbo355's Avatar
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    Re: My countach build

    Here are some shots of the door skin so far ,we lost our electric for a week here from hurricane ike so i didnt get to work on it this week but i did get some done over the weekend.

    The marks in the upper part of the door skin is from planishing the door skin to get the curve to fit the body corrctly since the curve is quite tight . i still nedd to do some gapping to get a proper gap all the way around the door but its getting close now i started to do some mud work on the top of the window frame to make sure my lines will be correct.









    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  4. #4
    Junior Member turbo355's Avatar
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    Re: My countach build

    I took a 6 month break between these pics and the last pics i had some customer work to catch up on and family time.

    I started back on it over the summer of 09 and decided i wanted to get the drivers door done and try to get the car ready to paint, i also had to finish up the front suspension as is was in need of lots of work.

    I moved the roof up to give the roof line and more accurate look, i wish i would have done this before i made the passenger as i had to go back and redo the window frame for that side to match the new roofline.

    I also completely reshaped the whole front air dam and front of the fenders as they where drooped in the front and looked very bad.

    Here are some pics of the work completed before i stopped last winter.






    You can see the back of the wheel flare in this pic i split it and widened it by 2in at the very bottom to match the 79-80 S2 style wheel flares,i did the same on the front of the flare also.








    Here you can see where i started to reform the lower air dam to be more accurate to the original.







    Here you can see i had to move the lower part of the air dam down ( where the brake ducts go) and reform the lower lip .




    Here you can see the drivers side fog light tucks in on the lower right corner i fixed this later on and didnt get a picture of it.



    This is the complete front air dam now with the lower scoops fixed the brake duct hole enlarged and more correct and the front trunk lid reshaped also ( the lower front edge was rounded instead of squared off).







    Here you can see the gaps on the trunk lid are not very good they kinda round off before they go into the trunk jam i fixed this next.












    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  5. #5
    Junior Member turbo355's Avatar
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    Re: My countach build

    Now comes the drivers side door i admit i should have taken more pics of the process but if there is anything not seen here you would like to know i can explane (hopefully) for anybody to understand.


    First i start at the back of the door and make the latch pocket.










    Then i make the lower extension, you will notice the lip on this piece this is where the skin will be welded to later on this also serves to help me see where the inner door frame is in relation to the body.






    Now i built the lower potion of the door , this was quite easy just a simple straight piece with the 90deg bends









    Ok now here is where my photo diary skills are lacking i got so busy building the door i stupidly forgot to take any pictures of the door frame being built and the inner door structure being built .

    Baiscaly the top door frame is made of two layers of .063 aluminum, an outer and a inner section welded together to form the window frame this makes the door quite rigid and strong across the top and still be light once the window channel was welded on this door is very strong across the top .















    You cant see it very well in this pic but the pocket in the fender where the door opens into i enclosed this section also so dirt and grim from the front tires wouldnt be able collect and get into the door jam something i had a problem with before.

    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  6. #6
    Junior Member turbo355's Avatar
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    Re: My countach build

    Here is the window regulator im decided to go with im changing the pass door to accept the regulator also this is much simpler that the original cable and pulley setup i was going to use les parts to fail.

    This regulator is out of a cavalier im not sure the year i will have to find out but i seems to work just fine i have some electric motors for the regulators so i will make them power instead of manual.














    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  7. #7
    Junior Member turbo355's Avatar
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    Re: My countach build

    Now i started on the outer door skin ,first i start making the top plate.









    Then i move to the actual door skin, first i planshed the skin to get the curve to match the quarter panel and the fender i left the skin long intentionally, so i could trim it to fit as i was welding it to the top plate,this whole process took about 2 hours to complete as you have to work slowly to make sure everything lines up and you dont wrinkle the skin .




    Here you can see my door gaps are very tight on the door to fender, later after i welded the skin on complete i can go back with a file and file fit my gaps.









    I didnt get any pics as i was building the scoop into the door but this was a simple process and shouldnt be hard to do if you got this far building the door.
    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  8. #8
    Junior Member turbo355's Avatar
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    Re: My countach build

    Now on to the primer stage for the front half.
























    At this point i have the front suspension complete , first coat of slick sand primer and the doors fitting half way decent gaps still need work and plenty of blocking.




    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  9. #9
    Junior Member turbo355's Avatar
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    Re: My countach build

    At this point the front half is ready to go i remade the front trunk hinge, and some other minor stuff, nothing major, the back half of the car mainly need some touch up work done nothing major on that end to get read for paint.

    Here is some outside shots.




















    Here it is ready for paint i dont have a booth since i dont spray that many cars so please forgive the country style paint job.LOL



















    Here is a pic of the turn signal bucket the big holes around the seal are for the trim rings i made that hold the covers for the lenses.

    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

  10. #10
    Junior Member turbo355's Avatar
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    Re: My countach build

    This was the new paint job, still need buffing and lot of finish work but getting there.

    The red interior is also going is was in need of a redo anyway.LOL

    You can see the trim rings setting in the turn signal opening in the pic also.




























































    Car pics here----->http://www.customcarblogs.com/gallery2/main.php?g2_itemId=1103

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