Proteus has developed 'state-of-the-art' aluminium body assembly techniques that ensure the aluminium bodies are produced with optimum strength, quality, and accuracy. To achieve this a suite of fourteen cast iron tools were produced to form the complete outer skin of the C-Type.

Pressing Process

We use high strength 5083 aluminium alloy. The cast iron tools are heated to 500 degrees, and then compressed air gently moves the material onto the tool surface. As the material is hot and in a super plastic state we achieve excellent definition and detail on the aluminium formings.

Secondary Operations

Once the panels are formed they are then taken out of press and put on a cooling frame which holds the shape and accuracy whilst cooling.

Each panel is then dimensionally and visually inspected before processing on to a five axis laser to be trimmed ready for assembly.

Once a panel set has been formed, trimmed, and inspected, the next stage is to assemble the panels together. This is completed by using a (TAGS) Tungsten Argon Gas Shielded welding process. The panels are clamped together in welding fixtures to control movement and limit heat distortion.

After completing the welding operation the body panels are then metal finished by highly skilled sheet metal workers to ensure that the bodies do not require any filling during the paint process, much the same as a modern day production car. The cars are worked on in high visibility light bays to guarantee any imperfections are removed prior to the paint process.