This is a post about the building of my 1929/30 reproduction ulster. In late 2014 while a student, I purchased a pile of Austin seven parts that vaguely resembled a car. A steering wheel or two, a couple of gear boxes, wheels for Africa and a chassis thrown in there. You get the picture... These were then stashed and carted around the top of the south Island of New Zealand for a year. I was moving from flat to flat and still a student. In that time I slowly worked out what I was going to do with my stash of parts, and after a lot of pondering and a persuasive nudge I settled on a reproduction ulster. Fast forward two and half years, I have established a firm plan and the first results from a lot of researching and learning are coming to fruit. With no prior background with automobiles, everything is a challenge and I am constantly learning. However I should quickly note that I have been very fortunate to have help and guidance from some very clever and generous people here in New Zealand and overseas. The overall goal is to build an accurate reproduction ulster to the best of my abilities that embodies the look and feel of the late twenties and early thirties. A car that performs well and captures all the successes and flaws of the ulster. That said, we shall see how things go.


I am currently working on the floor-pan, but also juggling with the chassis and rear diff. I will endeavour to keep this post up to date as progress is made.

The floor-pan outline being sketched out on plywood. This took a long time and involved a lot of eyeballing.




After the floor dimensions were settled this was all transferred on to metal. The edge was added and then two halves of the floor were cut out and folded.





Some more pictures showing the floor and now its shape.








This all done, I now started the task of lifting the edge of the floor up. This edge, being curved, has to be very slowly lifted. As it is lifted it distresses and forms waves. the excess metal needs to go somewhere and thus must be shrunk. Tucks are made and then cold shrunk with a hammer and suitable dolly.







Another photo bellow showing the edge being lifted with a tuck in place ready to be shrunk.




Next on the list was the front of the firewall. I chose this as it would allow me get a hand in for making the pressings, of which there are a few. This was most likely done originally with proper presses and swagging machines but I had to resort to good old hand tools.





Next on the list was the Prop tunnel. I made a Wooden form as a guide then made a paper pattern, transferred that to metal, lifted the edges and then rolled it over a pipe. In hindsight I should have cut out the front of the tube before i rolled it... but that's hindsight.







I am now tackling the rear part of the prop tunnel and the rest of the fire wall. I will update when I have made more progress. Here's what it all looks like so far.





As this is very much a work in progress, If anyone has any information about Ulsters and is willing to share. I would be very interested. I am always on the look out for info. Cheers Athow.

Hi Athow,
great stuff and totally fascinating to see how the build is going - keep up the good work!

Steve V.

Location: Polegate, East Sussex, United Kingdom

Amazing work Athow!

Please do keep us informed of progress.

Brilliant work.Put your questions on the forum,you'll get loads of help.
Two things I think are most important on building an ulster are correct looking instruments and headlamps.
Have you got a copy of Chris Goulds book on building an ulster?

Well done Athow, see you on the 8th

Location: NZ

Cheers Folks, Thanks A lot. Yes I most certainly do have Chris's book. Yes look forward to seeing you Ian soon. Cheers Athow.

Hi Athow,

What a great project and very impressive work on the floor pan. Well done and bon courage with your continuing build.

A seven month rebuild on my own Ulster rep is almost complete and I've learned a lot from this forum, where you'll always receive advice to your questions.

As has been said, the dash with correct instruments is an important feature and together with the seats, will make your car look more like the real thing.

Are you staying with an original brake set up?

Best wishes,

Bill

Location: Saumur, France

Thanks Bill, I am Not 100% sure what I will do re brakes. I Currently have a independent brake set up on the chassis I have. But while I bring it to Ulster specs I may change it to a coupled set up. It will stay original cables either way. Re dash and seats, I most definitely will put in correct instruments. I understand that Ulsters may have originally had pneumatic air cushions, so I will do that as well. But jee wizz that's a long way off.
Cheers, Athow

Good post Athow. It was great to meet you three months back and see your project. You are making good progress. Bruce

Location: New Zealand, Whangarei

Bruce how about starting a thread and posting pictures of your project too, I think people here will find it of interest, and you never know might even inspire a few more Kiwis to come along to the body building workshops.

Location: NZ

Just seen your fascinating post Athlow and good to be able to put a face to a name ! This must rank as one of the most competent restorations especially by a youngster, where did you learn all your metalwork skills ? A great effort and I hope you keep all of us 'posted' regarding the car's progress. Please do not hesitate to contact me if you need to source any parts but obviously any larger/heavier ones will be quite expensive to send out to NZ. Keep up the good work. James

Location: Ferring, Worthing, West Sussex

Thanks James, much appreciated. I was going to send you the link but you found my post. Apart from a few some hints and tips with metal work from Ian and Joss here in NZ, I'm all self taught. I must admit that means a lot of cockups, but hey that's how you learn. Thanks for your help and support I'll be sure to keep you posted.
Athow

Location: New Zealand