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    1. Kit: Pocher, by (Yearly Subscriber) Jo NZ is online now
      Builder Last Online: Jan 2023 Show Printable Version Email this Page
      Model Scale: 1/8 Rating:  (3 votes - 5.00 average) Thanks: 8
      Started: 05-07-14 Build Revisions: Never  
      Supported Includes Transkit Attribution Scratch Built
      Translations Build in Progress

      I used to work with some nice people who owned a model shop (Grand Prix Models) that sold Pocher kits. In the 1980s I built the Rolls Torpedo Cabriolet and the first Bugatti T50 as display models (where are they now?) and an Alfa Muletto for a customer. The Alfa was far and away the worst of the three - not surprisingly, as the kit was probably 20 years older than the Bugatti. I alway wanted to build a Pocher for myself, but have only recently got around to it, so I bought - you guessed it - The Alfa! I love the shape, and it's far enough away now to forget trying to wrestle the firewall into the chassis using all three hands.
      I discovered this forum while I was looking for an Alfa kit, and have taken on board the trials, tribulations and modifications made by all on the forum - with particular thanks to Dougritt, his thread really got me moving on the Alfa.

      Basic starting point - I wanted to build one in Burgundy red with swept front wings but the Monza tail. This was (still is?) the target:

      Pocher 1/8 Alfa Monza revisited-ref-337-jpg

      Of course it will probably change through the build....

      PS When selling the Pocher kits, we [I]always[/I] got asked what tools were needed to build it. The stock answer was - a small screwdriver - and a good Psychiatrist....


      Pocher 1/8 Alfa Monza revisited
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  1. Dougritt's Avatar VIP/Sponsor
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    I really like the heat shield solution and the floor is totally cool!
    QUOTE QUOTE #107

  2. Dougritt's Avatar VIP/Sponsor
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    Well done!
    QUOTE QUOTE #108

  3. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    Thanks Doug. I get a real kick out of finding material that looks right ( e.g. for the floor) in a hardware store!


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #109

  4. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    The body is ready for painting (or it was until I saw the defects in the photos!) and I'm waiting for the weather to improve before I spray it. I have block sanded it using 150 grit, initially, to get it flat, continuing to 800 grit before priming. There are a lot of areas where the plastic has warped or slumped that need flatting off.

    In the meantime, here is the front bulhead - all holes have been filled, and new ones drilled in the correct locations. I have removed the protruding swaging lines - they should be indented, however I decided not to go that far...
    I've also filled and recut the cutout for the steering column. I found a ready supply of red plastic in the wheel building jigs, and used gap-filling cyano to fix the plug. It works pretty well.

    Pocher 1/8 Alfa Monza revisited-img_2300-jpg

    I've also machined the fuse boxes and cable clamps, from a material called Tufnol - it's resin Pocher 1/8 Alfa Monza revisited bonded fabric, and it's been in my scrap box for a while (30 years ! This is when you say to yourself - "I knew it would come in handy one day..."). Tufnol was the nearest I could get to the brown bakelite used.

    Pocher 1/8 Alfa Monza revisited-img_2304-jpg


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #110

  5. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    After a little break (well nearly a year) when I started a Brooklands Bentley, among other things, I've come to an impasse... both cars need louvred bonnets. I made the bones of a press tool a long time ago but never made the tools - it went on the "too hard" pile because I'd read that the forming was done in the female half, and I couldn't work out how to make it.
    Then I saw some crude tooling producing perfect louvres on YouTube... With the male side producing the shape.
    Here's the press tool

    Pocher 1/8 Alfa Monza revisited-img_2512-jpg

    and the first attempt at a punch

    Pocher 1/8 Alfa Monza revisited-img_2516-jpg

    and die

    Pocher 1/8 Alfa Monza revisited-img_2506-jpg

    The first tool deformed the metal on the second punch, so I made one with more land area, and also set the cutting edge aligned with the edge of the tool so that it's easy to stone to sharpen it. The width of the slot in the die doesn't seem to be important - but getting a good alignment of the cutting edge and the edge of the slot is

    Pocher 1/8 Alfa Monza revisited-img_2511-jpg

    Louvres from the first tool are on the left. See the distortion behind the louvre. I also made the second punch a bit longer to better replicate the original - the Pocher louvres are about 1.5mm too short. Material is 0.4mm Aluminium sheet (not annealed, Dan, but I think I will anneal the top panels to get the curvature)

    Pocher 1/8 Alfa Monza revisited-img_2514-jpg

    The first test piece, with correct alignment. Louvre spacing is made by machining the die width after the slot to the correct spacing, and butting up the previous louvre. This has a thin coat of etch primer Pocher 1/8 Alfa Monza revisited

    Pocher 1/8 Alfa Monza revisited-img_2518-jpg

    ...and painted. Excuse the lumps in the paint, I was sanding Pocher 1/8 Alfa Monza revisited elsewhere in the garage and opened the outside door on a windy day...
    Incidentally this is a rattle can of paint I had handy - Austin Morris Cherry Red

    Pocher 1/8 Alfa Monza revisited-img_2525-jpg

    Onto the real thing - the first panel for the Alfa (bonnet side, top left)

    Pocher 1/8 Alfa Monza revisited-img_2527-jpg

    The second - the right side. There is a small return on the bottom, created with a squeeze in the vice over 1/8" steel rod. The vice soft jaws are cut from an old leather belt.

    Pocher 1/8 Alfa Monza revisited-img_2531-jpg

    Pocher 1/8 Alfa Monza revisited-img_2533-jpg

    The first set of louvres. Before I punch the second set, I need to machine a slot in the die holder to provide relief for the return on the panel

    Pocher 1/8 Alfa Monza revisited-img_2535-jpg

    Jo


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #111

  6. MODEL A MODEL's Avatar Yearly Subscriber
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    don
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    Hi Jo!
    It all looks pretty good to me! -Have you time to try another experiment? I've noticed on some 1:1 Pocher 1/8 Alfa Monza revisited louvers a hole was drilled at the ends to help start and control the tearing of the metal sheet. I haven't tried this but since my Model A has some big louvers, I've been studying all the different ways that people have thought of . . . making louvers.

    Your photo with the painted and bare metal panels, look pretty good to me! I don't think you need a female tool. But for another experiment? put some thin tape on your male die, (3M transparent tape is fine) wax it, as a release. Make a removable container where your "female" tool will be, and fill it with almost anything like epoxy Pocher 1/8 Alfa Monza revisited , casting Pocher 1/8 Alfa Monza revisited resin Pocher 1/8 Alfa Monza revisited , . . . and lower your male die into it. Let it cure Pocher 1/8 Alfa Monza revisited of course, and raise the male die. -The lower die, the female part of the conforming die doesn't really do anything but restore the louvered metals shape. The real work is at the cutting edge. Two-part epoxies sold at hardware shops should be able to handle the aluminum.

    I do go on! I'm sorry!

    Your louvers look great! -Don
    QUOTE QUOTE #112

  7. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    So - ready for fitting and trimming - the bonnet side panels

    Pocher 1/8 Alfa Monza revisited-img_2538-jpg

    And the scrap....

    Pocher 1/8 Alfa Monza revisited-img_2540-jpg

    Must get some more 0.4mm sheet


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #113

  8. ThierryD86's Avatar VIP/Sponsor
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    I'm very inquisitive, Jo NZ !
    How did you make your punch and your die ?
    QUOTE QUOTE #114

  9. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    The die was a strip of 2mm thick steel with a 2mm slot milled into it. The punch was cut from scrap steel - like this

    Pocher 1/8 Alfa Monza revisited-img_2519-jpg

    and being of indeterminate ancestry is probably a bit soft. I milled it to leave a 1.3mm high rectangle and then created the rounded profile of the inside of the louvre with files. The cutting edge is honed on an oilstone to ensure a sharp edge. Making the tools is easy - but you can see from the scrap pile that getting a consistent, flat, non-angled and clean cut is where the magic comes in. It took several evenings to get it right. Even mis-counting the louvres is a trap for the unwary....


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #115

  10. Jo NZ's Avatar Yearly Subscriber
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    Starting to fit the bonnet side panels

    Pocher 1/8 Alfa Monza revisited-img_2541-jpg

    Pocher 1/8 Alfa Monza revisited-img_2542-jpg

    Pocher 1/8 Alfa Monza revisited-img_2544-jpg

    Pocher 1/8 Alfa Monza revisited-img_2546-jpg


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #116

  11. PROPELLER's Avatar VIP/Sponsor
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    Dan
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    Very impressive Jo.
    Congrats!
    QUOTE QUOTE #117

  12. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    I've made the die for the top louvres. They taper so vary in length, but the difference between the front end vent and the rear is only about 2mm over 12 vents. I decided to make them all the same length - I can always go back and produce 12 forming tools if don't like it...

    I annealed the top panel. I tried my heatgun but at 1600W it doesn't get hot Pocher 1/8 Alfa Monza revisited enough. Flame annealing with a gas torch works fine - coat the sheet with soap, as soon as it goes brown/black it's done. Any more and it will start to slump.

    The top and side being fitted

    Pocher 1/8 Alfa Monza revisited-img_2551-jpg

    The curve on the corner of the bonnet is tapered. I found the ideal forming tool - a jewellers ring mandrel


    Pocher 1/8 Alfa Monza revisited-img_2556-jpg

    Nearly fitted - I'll make the other side before I get everything trimmed


    Pocher 1/8 Alfa Monza revisited-img_2559-jpg

    Pocher 1/8 Alfa Monza revisited-img_2558-jpg


    Pocher 1/8 Alfa Monza revisited
    Last edited by Jo NZ; 07-23-17 at 01:32 AM.
    QUOTE QUOTE #118

  13. markus68's Avatar VIP/Sponsor
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    Very instructive. My next project will be a monza and i have to do the same some day. Markus
    QUOTE QUOTE #119

  14. Jo NZ's Avatar Yearly Subscriber
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    Jo
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    The exhaust side

    Pocher 1/8 Alfa Monza revisited-img_2561-jpg

    Pocher 1/8 Alfa Monza revisited-img_2563-jpg


    Pocher 1/8 Alfa Monza revisited
    QUOTE QUOTE #120

  15. MODEL A MODEL's Avatar Yearly Subscriber
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    don
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    -craftsmanship is a lifelong project of
    self-construction and self determination
    QUOTE QUOTE #121

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