Jeff Sexton

Sunday, January 17, 2016

Testing the Body and Frame Fit

One well known problem with this Pocher classic is that assembled "as-is", and hood appears to be about a quarter of an inch too short. The hood is correct though. The real problem is that the radiator should tilt back at a significant angle. But assemble "as-is", or as directed, and the radiator ends up at 90 degrees. A secondary issue is that with the radiator at the right angle, the engine doesn't fit. It is too close at the front.

There are a few fixes to do; changing the angle on various connecting parts to the radiator, moving the engine back, and altering the radiator so the brass fill does not really connect to the hood ornament. To get the engine to fit requires a pretty significant change. But I am going to get that quarter inch by doing several smaller changes to everything.

 On the hood ornament, the brass part passes up through the nose body piece. This has to line up. By not having that part there, the nose can be shifted back enough to make the hood fit, but the radiator inside does not have to shift back so much that the engine doesn't fit.

Rather than leave that part out, I ground off one side of it's base. Now it sits closer to the back of the radiator. I can pass up outside the body, and the radiator can still sit ever so slightly forward. I haven't seen this suggested anyplace else, but it buys a couple of millimeters.

I still have to change the angle of holes for the support rod and other connecting parts, and I will have to move the engine a little, but not so much that a new front support for the engine will have to be made. From my rough assembly shown here, it looks like it will all work.

As part of all this, the main body piece has been significant altered to slide on the frame just right. The pieces are very large, thick casts of plastic. Fitting them is like sculpting.

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