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So, what is left is a flexible mid-bulkhead panel that will quite easily bend to a new shape. The change is subtle - only 40mm in height difference in the middle so the saw-blade cut width of about 1mm is plenty.
The middle sections of the mid-bulkhead also required a slight 'tweek' downward so I cut a 'V' right through the moulding from the mid-window to the point where the angle change starts, then relieved the thickness - again to about 3mm so it could be flexed easily.
widened the roof by about eight inches. When the time comes we'll fill-in the centre hole and reinforce the whole area by 'laying-up' new GRP inside and out.
Back in 1967 the four original P4's (yes, only 4) were hand-made. by craftsmen with simple templates, patterns and skilful judgement - a world away from modern, computer-generated designs. Each of the four was slightly different from the others as a result. We used the same eyeball/judgement method to determine the new roof width and shape of the mid bulkhead. The radius around the top of the windscreen is fairy consistent so the curvature of the front of the roof panels could remain unchanged. But the curvature at the back was significantly different. We tackled this problem by making four long saw-cuts in each roof panel from the back to a couple of inches from the front. This allowed the rear curvature of the roof to flex and roughly match the new shape of the mid bulkhead. It was all temporarily held in place with riveted aluminium plates. You can see that we've
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