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toolman

Heavy Duty frame rails and connectors

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Just returned from vacation in Tokyo.   While travelling the rural area, I manage a get a picture{not a good one though} of a Japanese Snap On Tool Truck.

IMG_0590.JPG.da7af4c94f855fbea27f12fc474272cb.JPG  I think it is only about 12' long box van.   Tiny in US standards. 

Snap On Tools  in Japan sell for double of US prices too.

 

 However, when I returned home. there was a Big Surprise for me.   The Greddy S30 Rocket Bunny Full Body kit was waiting for me.  The shipping box was about 18" x 24" x 8 foot long thick card board.   It was packed very well also.   These kits are only manufactured when you order it.   It 

took 9 months before I received it.  But as the pictures show the quality and workmanship was top notch.

IMG_0239.JPG.9500c1f9b6e3e57319f057bbc4ef5735.JPG The Rocket Bunny Kit consists of one- Front Lower Panel, one Front Bumper, two

Front Fenders, two-Rear Fender Flares, one Rear Spoiler and bag of Miscellaneous Mounting bolts/ Fender Gap Inserts.

I am including detail pic of the individual fiberglass parts so their  quality workmanship can be seen.

IMG_0243.JPG.950586822a2df9da919a0847315e5a19.JPG  Front view of parts

 

IMG_0244.JPG.ec64b3af7558f7d3b67f1eb5504c4eb4.JPG  Rear View of Parts

 

351284975_IMG_0457(1).JPG.4d4025e02ae6dd503f60ea22d30ad021.JPG  Inside of Front Lower Panel( note-the smooth figerglass layout and finishing

sanding of the edges.}

781719614_IMG_0459(1).JPG.78d19281006a2cda203f36955b4d5d11.JPG Backside of Front Fender

 

2074894473_IMG_0460(1).JPG.6da2eb7ddef33a1609e9ee44cac162ea.JPG Inside of Rear Flares

 

597498190_IMG_0465(1).JPG.ec64356e02f289497b2a8d09b72af024.JPG  Outside view of Front Lower Panel

Note-very detailed with Turn Signal mounting holes.

 

IMG_0464.JPG.6a64791eb389e01471615856ca18f5aa.JPG Exterior view- smooth and detailed

 

709844053_IMG_0466(1).JPG.a1a9c59b9368731763fae5815afa014e.JPG  Inside view 0f Front Bumper

Note- Front Bumper Mounting insert

IMG_0471.JPG.44966595d79aa38bd013e7ef12395ba1.JPG Top View-Front Bumper

 

330884940_IMG_0473(1).JPG.0222b3a86a6efbd3796ce0ad56594280.JPG Rear View-Rear Spoiler

 

IMG_0474.JPG.f81ea0118b2fdcaae5c1c0c7a9a3a2d4.JPG Front view-Rear Spoiler

 

The real test of a good body kit is its fitment.   Those cheap Chinese kits usually require a lot of manhours to make them to look decent.

IMG_0211.JPG.55cee7e0d2a9d9525610c1209f9bb467.JPGFront bumper and lower front panel

 

Left front Flare

 

IMG_0208.JPG.0c5b90de0d3a0618462ad3fe84bf3a2b.JPG Right Front flare

 

IMG_0206.JPG.ae464eedc4c77ad40ae5ecca1428b9b7.JPG  Left rear flare(note separate door flare

 

1812684570_IMG_0237(1).JPG.9c235801c954365c97b3920b004b92ef.JPG  Side view of Rocket Bunny Body kit

 

IMG_0238.JPG.946bd3a719e5edc14aa6d977c09dff4a.JPG Front view of Rocket Bunny Kit

 

The Front Flares only require trimming the fender to make it work.   The rear flares will require more manhours to fill the gap between the inner and outer quarter panels and the outer flare.

 

 

 

Edited by toolman
photo correction, text cprrected

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Left Front Fender modifications for Greddy Flares.

After placing Rocket Bunny flare against the fender then mark the area to be removed with a black marker pen.

1562891533_IMG_0237(1).JPG.f8f7ec4dfdc6e3639faeca609c5781ad.JPG

 

A Electric shears was used to cut the major removal cuts.

IMG_0233.JPG.51bc50101261af8b7c4c81a7b66e0c50.JPG  Always cut carefully to prevent "over cutting too much".

         

IMG_0235.JPG.66657f4fe577fe74c5bfb7d59cd6d633.JPG A Hand Nibbler was used in the Finishing Cuts.

 

The Finished Product

IMG_0205.JPG.bc4c37bba208b88069a134f889929cd0.JPG

 

Rear Wheel Housing Modifications for the Rear Flares-

Like the Front flare. the Rear Rocket Bunny Flares are mocked against the existing quarter panel.

IMG_0228.JPG.fc09a3856f549a268dd09050d650e0b2.JPG The Outer edge of the flare is marked

with a Black Marker Pen.

In my case, I had already removed the original wheel opening edge when I constructed metal flares previously, there was a little less

of the quarter panel to remove.

IMG_0437.JPG.56b38f45c86517154c3ed4256a02da28.JPG Bottom view of the wheel well(looking upward from the ground)

As the photos show the gap between the quarter panel and wheel housing  was only about 3/4".  So I could have just squeeze both panels together

and mig welded them together.   But I decided to cut an additional 3" higher to give more tire clearance and allow more body drop.  Better to do it

now instead of later.

IMG_E0714.JPG.f8b3498cbf81cf974aa6e554f3f6de80.JPGSide view of additional cutout.

 

But now, the gap  between quarter panel and wheel housing increased by about 2 1/2".   So fillers had to made to fill these gaps.

IMG_0737.JPG.953398b2f5b9592e59114c0ec33d8a98.JPG Patch being mocked up.

 

The Sheetmetal Roller was utilized roll the metal to match the wheel housing.

IMG_0739.JPG.fc31c65fd34af22dd831d4df146b6ddc.JPG    IMG_0740.JPG.34ae112dd47f5e2f6464152473f8ec4a.JPG  making gap fillers

 

IMG_0748.JPG.495105d9e483a24d0f9d84e52e7439c4.JPGOverall view of the gap fillers

IMG_E0743.JPG.2d5e5332f6c29fba14cfa4c7265b43be.JPG      IMG_0744.JPG.c2a6d05cb11573c47f4007448dea6f95.JPG

An Air Punch/Flanger is used to flange the edges of the fillers to make the filler surface smooth and stronger.

 

Cleco pins and vise grips hold the gap filler plates in place for welding.

IMG_0747.JPG.15611b3babf9a542e1683c812166ebfd.JPG

 

The front of the Left wheel well housing needed a patch so a paper template was created.

IMG_0754.JPG.05725a33688183921b3cb501ab583401.JPGNote- the bottom of this patch had to be

"rolled over" by making a slit on the bottom then hammer welded the slit closed.

 

The patch started as a flat piece of 20 gauge sheet metal that heated with a torch to soften it.

IMG_0752.JPG.c621bb429ab2802e72cce36ae2734b47.JPG     IMG_0741.JPG.325e158b81ab7b911be2c299464ca9f9.JPG

 

Then was hammered with a Shaping Hammer on a Leather Shot Bag to shape the patch.

 

IMG_0753.JPG.3b9b26fb71693b3fb01c828a60ff7754.JPG Additional pounding with a Ball Peen Hammmer.

 

IMG_0757.JPG.f2eb6904ebb77b3a82ce0551ca4f8062.JPG  The Patch fitted into place then tack welded in.

 

The inside portion of the wheel well patch was covered with Fusor Seam Sealer.IMG_0776.JPG.bcc7dd321e65ffe07ba00407b60e84c0.JPG

 

IMG_E0780.JPG.40f79ff8adc983fba34f0d215440f413.JPG  Inside of the wheel housing,  EverCoat  Epoxy Seam Sealer was applied over all welds and all seams.    Polyurethane paint will be spray painted over all of the repaired areas.    The inside wheel well areas will also be covered with

Urethane BedLiner for additional protection.

 

 

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Thank you Nelsonian,  Here are additional pics of flaring modifications.

IMG_E0788.JPG.88e5afc75208d5f5796673b432bdbe49.JPGAfter sealing the inner top section of the wheel housing, area was painted with polyurethane paint.

 

IMG_E0783.JPG.42841c3f58b9b0ae8e8ad52945a508bf.JPG Bottom view of wheel well housing after

painting.

 

IMG_0782.JPG.37ed038736e1071f5f8d8d7b2f7fc97d.JPG  Overall view of rear flaring modifications

 

 

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