Creating the Morgan #2: Radiator Insert Chapter 04

  • Advertise with us
Blog entry by DaveS2 posted 06-17-2022 03:18 PM 455 reads 0 times favorited 4 comments Add to Favorites Watch
« Part 1: The Classic One - -The Morgan Part 2 of Creating the Morgan series Part 3: Creating the Wheel Space, Part 03 »

I decided to do a quick post on creating the Radiator insert (Part 4A) and the radiator vanes (Part 4B). I knew that I needed to make the vanes to fit the insert part but was not sure how to proceed. Thinking about it I came up with the following solution (I’m sure there are more elegant ways to do this, but it worked for me, and I still have all 10 digits)

Create Part 4A by milling the stock to the correct thickness and make it oversize so that working with it is safe. I used painters tape and spray adhesive to put the template on the stock. Cut to oversize on the bandsaw and then sand to size and shape.

Select the stock for the vanes (Part 4B) making sure that there is sufficient thickness to accommodate the next steps

Attach the vane stock to a larger piece of material with double stick tape. This will provide a safe way to cut the vanes on the bandsaw.

Using a compass, scribe the vane outer and inner dimension on the stock.

cut the outer radius oversize and sand to final dimension:

Repeat by cutting the inner radius and sand to final shape and thickness.

Measure the 2.5mm thickness of the vanes and set the bandsaw fence to that dimension. Use 1/4” MDF or ply or hard board to create a zero clearance table insert.

With the concave side down, push the vane blank through the cut. repeat until you have the needed number of vane blanks

Sand the pieces if needed and apply to Part 4A. I start with the one in the middle and use the other blanks as spacers being careful not to glue the spacer in. I use a medium CA for this particular construction.

Glue all the vanes (Part 4B) on the insert (Part A) and then sand to final size and shape.

After this is completed and dry fit into Part 4C, any additional sanding adjustment of the shape can be one for a perfect fit.

I hope this helps anyone making this particular plan.

Today I start fabricating the tires, rims, and spokes. More to follow.


-- DaveS2, Canton GA aka pdwoodwerkz

4 comments so far

View Dutchy's profile


4397 posts in 3660 days

#1 posted 06-17-2022 03:50 PM

One of the hardest parts. You did it the way it was drawn! Very nice and thanks for the blog, and yes for others this can help.


View DaveS2's profile


56 posts in 104 days

#2 posted 06-17-2022 04:14 PM

Thanks Jan. Once the process is thought out, it all makes sense but initially it’s a bit overwhelming. The piece in the blog was actually a trial run before making the actual final part.

-- DaveS2, Canton GA aka pdwoodwerkz

View Eric's profile


5738 posts in 1365 days

#3 posted 06-18-2022 10:02 AM

Looks like you nailed it Dave, I had forgotten about using hardboard for a zero clearance. Some time ago I had a piece with multiple cuts along the sides for quick setup on the table saw.

-- Eric, building the dream. the "Loft"

View crowie's profile


5521 posts in 3443 days

#4 posted 06-22-2022 09:31 AM

So nicely done, looks the real deal.

-- Lifes good, Enjoy each new day...... Cheers from "On Top DownUnder" Crowie

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics