WFSZ16 03

Another week on the zagato. Started making a jig for the front subframe mountingpoints

All 4 points secured in place

Adjusting the height

Oops. That chassisrail is bent and doesn’t line up with the jig

So i drilled the spotwelds to gain access

First dent knocked oud

The front of the innerwing was pushed in by the chassisrail so i cut it out

And made a new front panel

Repaitlring the firewall

Made a template

And welded in

Passengerside innerwing had a lot of damage, dents and stresscracks

Half of the spotwelds were allready broken loose

Luckily Huib had a complete passengersidecorner from a coupe in stock that he kindly donated for the zagatoproject

I carefully drilled out all spotwelds from the firewall

And drilled out the spotwelds for the chassisrail on the original firewall

Fixated the front 4 subframepoints to the rest of the car

Some more rustdamage on the driverside innerwing

Repaired

Started to build the front end up again to check for fitting and alignment

Starting to look like a car again

Top!

First trialfit of all the new panels

Adjusted and modified the new hinges

Making the new panel for the inside of the frontwing

Cut out the old pocket of the old panel to allow the door to open

Tacked in the new panel

Fitting the doors

Rearranged the jig and fixated because it appeared to have moved a little bit in the past weeks

Another small week on the zagato. I put the frontclip on the car but i couldn’t get it to line up nice because the chassislegs are now in the correct position and the insideparts of the frontclip were all bent and rotten

So i started to take the front clip apart in all seperate pieces

The scuttle cleaned up nice

Headlightbowls and supportbrackets were bent and prevously very badly repaired and patched up

So i hammered the best pieces flat to have a template for the new pieces. Checked and measured everything on the white zagato in the workshop

A bit of stretching and shrinking before tipping over the edge to create a nice and sharp line

One side done

Fabricated all the brackets and supports

Start of the new bottompart of the bonnethingesupportpanel

And again a bit of shrinking to make the correct curve

Another week on the zagato. The bonnethinges were bent and had a lot of play on the hingepins making it impossible to make everything line up constantly

So i fabricated new hinges from 2mm thick steel

And new supportplates to go inbetween the hinges and the lower part of the frontpanel

Making a template for the new headlightbowls

Marking the edged

Roughly in shape. I will cut the holes for the headlights and frames when it is clear which headlights will be used

Marking the steel to fabricate a new toppane for the front

A bit of shrinking to get the correct curve

Finished toppanel including the frontcorners of the frontwings

Making a template of the frontwingtopsection. The wings that were on the car were already a patchwork of precious repairs, rusty and damaged so they will be fabricated new

Wheeling the panel to create the concave shape of the top before tipping over the edges

Making a template of the lower valance. Only half of it so i can mirror the other half to create a symmetric front. So i made the template of the least deformed side of the old part

Transferring the template on steel

And wheeling the panel to create the right compound curve en close up the reliefcut i made in the cornersections

Reliefcut closed and the corner formed and welded it up

Needs a bit more shape so wheeling it again with a rounder lower wheel

Dank weer! Alle stappen zijn goed te volgen op deze manier 👍

Another week on the zagato. I started to make a gutter curved to match the curve of the bonnet

Carefully welded it to the wingtop to control heatdistortion

Making themplates of the wing in 4 pieces to make it a little easier to handle and control the stretching and shrinking

First the front uppersection

Made the lip on the wheelarch

Rounded the front corner

Welded uo and smoothed

Rearsection is easier with less shapes so that can be made in one piece

Basic shape. Wheeled it to get the curve

Joined the rearsection to the front uppersection

Screwed it with a little selftapper every 50mm to the wingtop and then doublecut it to buttweld the pieces together. Very careful and slowly to control heatdistortion again

All welded up

Another week om the zagato. Start of a new rearsection of the left frontwing. Cut out the template and made the folds

Wheeling to get the shape

New front uppersection

Wheeled for the shape

And made the wheelarch

New topsection and the shaped gutter to line up with the curve of the bonnet

Joined all the sections to make a complete wing

Shaping the lower frontsection

And joined it to the right frontwing

Same on the left wing

The wingsupport needed to be replaced. It was bent and welded to heavy on the innerwing

So i cut it out

And made a new piece for the inner wing

And a couple of new wingsupports

New bonnethinges roughly cut out of 8mm steelplate with the plasmacutter

And shaped them with the beltsander

New plates for the hinges where they are bolted to the bonnet

This week started with finishing the new bonnethinges

And started putting the front back together

Then tried the complete frontclip together

Amd on the car. The white zagato turned out to be a little off here and there so my templates were not as perfect as i would have wished

First some finetuning on the frontvalance

The frontpieces perfected

Bonnethinges on the bonnet to try that on tr car for fitment

Nice and square

Valance on. Still a bit oversize here and there

Made a new lip to line up with the grille

Almost perfect

Drivers side wing on

The end of the top needed to be a bit lower to line up with the door and the rearsection moved a little backwards. The exces now on top of the doorskin has some extra material to fold over the edge later on. The middle needed around 30mm added to it
Zagato’s were handbuilt so no 2 cars are the same. Just like a giant jigsaw to make everything line up perfectly

Another week on the zagato. First i welded up the wing

Cut the end to size

Folded the flange and hammered it around the innerpiece

Then i noticed the bulkhead was pushed to the passengerside and being a bit to narrow

All subframepoints are perfect in place so i will start from there and work my way upwards. Cleaned the crossmember

Removed the vertical chassisleg from the firewall

New edges

Bottomsection was missing a piece

New supportbracket for the valance

Cleaned the inside and painted

Closed up

New frontsection welded in

Vertical chassislegs repaired and blasted the inside

Perfectly alligned the drilled out spotwelds

Building up the drivers side

Needs some adjustments on the tops of the innerwings