Radiator Cowl Reproduction, Update #3,

["Glenn A. Merrell" <gmerrel@domain.elided>]

Greetings All,
	For those of you whom have been following this subject, I am in the
process of having the original Stag radiator cowl set reproduced, PN's
312298 (Cowl upper) and 312299 (Cowl lower), and possibly adding PN
313090 Deflector Shield Assy' for an additional cost.  These parts are
NLS, out of production, no NOS or used to be found.  They were installed
on US and Aussie Stags primarily.  To date, I have about 25 requests for
the two piece cowl set.  Cost goal was to be $150-$200 US for the two
piece set, an exact reproduction, with an optional mounting bracket kit
to fit Mark I style radiators.  The Deflector will be an additional
cost.

	Thanks go to Tim Buja, who has briefly provided his three piece set to
be used as production templates and estimating set while his Stag is in
restoration.   I have been visiting numerous fabrication shops in order
to obtain fabrication ideas and costs.  Several ideas have come up as a
result of these visits.

	First off, it appears that my machinist buddies would gladly build the
tooling for about $3-$4K (which is what I had planned for costs), but
they are currently swamped with work for at least a year.  Tooling at
any other facility would cost upwards of $10-$30K for normal two half
metal press tooling, and was never part of the plan for this short of a
run.  So this is not cost effective for a 25 piece run, unless there is
a Stag Owner CNC machinist out there who will turn out the necessary
tooling for a specified press at or near cost, (or a Stag Owner CNC
machinist here in Denver, I have access to CNC equipment free on
weekends), or the BMIHT supplies me with leads to, or, the original
tooling.
	Yes, I have a letter out to the BMIHT looking for drawings and
tooling.  
	Yes, I do have a local manufacturers rep looking into a stamped 25
piece quantity for about $5K.  I'll keep my fingers crossed for that
one, until I hear back around the second week of January.

	Second, yes I have tried the SOCTFL route, but there is no interest in
25 pieces, 1000 pieces maybe would generate some interest.  Since there
is little demand for the cowl in the UK as a functional item, and SOCTFL
parts are mainly supplied to members, I doubt if I will see any solution
there.  

	Third, I do have some interest in production in the UK, but only for
100 pieces or more, and no set price yet.  So, if I get some additional
interest around that quantity, I will recheck that option.  This company
produces radiator cowls for Jags and others British cars mostly in
fiberglass one piece units, and possibly, may be the location of the
original tooling.  One piece cowls can not be practically installed on a
Stag since there is no room to get around the fan, and the fan can not
be installed once the cowl is in place, hence, two piece cowl.

	Alternatives for production include:

-hydroforming, using one half of the tooling and a hydraulic oil press
that forms the steel as the pressure is applied to the hydraulic
bladder.  This results in about 1/2 of the tooling costs, but an almostn
exact replica, still, not cost effective for 25 pieces; 

-having an old aircraft tinner craft them to a hardwood template die,
made from aluminum, a close look after painted black, within the cost
range, but produced one-at-a-time by hand on an "English Mill", and is
not original, but he is a quality oriented old timer.  Maybe he can do
one or two a week;

-having the cowls made of carbon fiber composite, which is stronger than
fiberglass, can be made to look very much like the original steel
stamping, adding a slight thickness and steel inserts at the bolting
positions for rigidity.  This most likely would have been the next
logical progression for the cowl anyway, but is not original.  Clear
advantage of this type of reproduction is cost and strength, since the
original cowl set can be used as a template to make the mould upper and
lower parts, and production is simplified.  Here, when the left motor
mount sags or the torquatrol unit starts getting wobbly, the fan hits
the cowl, a noise is generated letting you know that it is time to fix
something before you loose the radiator or lower hose.

	The root of this email is the need to get the production numbers up to
justify the steel stamped part or, make the set out of carbon Fiber
composite.  A 50 piece order would justify the tooling for a hydropress
method, or possibly steel/rubber die (lower template is steel, upper
template die is rubber), but cost will be $200-$250 or more for the two
piece set.  My main goal still is an original spec reproduction, but in
the end, I want the function more than the exact originality.  Several
of the interested folks have expressed buying the two piece set at
prices up to $300 US.  I personally think that price is too costly for
these parts, and I'd do composite first.

	If there are any others, other than those who have currently expressed
interest in a cowl set and are on my list, who wish to be included in
buying this part set, speak up now and give me a committment. 
Otherwise, I will cost out the project with those numbers who have
spoken up with a request for the cowl set.  If there are those of you on
the cowl list who want only an original steel stamped part, I need to
know that also.  A carbon fiber composite mould will only cost about
$500 to $1000 to build, so producing 10 pieces can be cost effective if
there is no increased demand for the cowl set.

Sincere Regards and Happy Holidays to All,
Glenn Merrell
'73 Mark II Stag, USA Model, LE23398U