Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

I have those same style holes for speakers in my doors! I can't wait till I start welding in patch panels. Give Harley a little lovin for me makes me hug my Pups tighter.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Thanks Ray,

You know how I feel about all animals.

So this girl really saddens me.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Got a message from @forddan @mercdan last week to ask if I would be interested in a pair of used wing mirrors for the Galaxy.

Of course, and at £20.00 for the pair it was a no brainier.

So next thing he sent a pic with the message to say he had them.

https://i294.photobucket.com/albums/...psgmxojurs.jpg

This afternoon he called to ask if I was in a hurry, should he deliver.

Of course I said yes please and an hour later he was here in one of sin George’s cars,a hot little red Ford Fiesta, lowered and on alloys.

Delivered, Harley had to inspect, in spite of not doing too well.

One needs a new glass.

https://i294.photobucket.com/albums/...psgvo4mg20.jpg

Covers need some paint.

https://i294.photobucket.com/albums/...pszk24osrf.jpg

After Dan left, I packed them away for future reference, well, after tomorrow as the Galaxy got dropped off this afternoon for a full service and new discs, pads etc.


Harley came and settled down on my leg, again, even the way she is sleeping, not the usual way.

Old age sucks.

https://i294.photobucket.com/albums/...psy7i79mok.jpg

Weekend over again, got a fire tonight, so the room is warm.

Thanks for checking in.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Took the Galaxy in for a service today.

Remember when I bought the car, I was told the brakes were in desperate need of a service.

They were.having done about 250 miles since then they went very bad last weekend when I fetched the furniture for Sally.

Weirdly, I never noticed till I got home that there was a message on the dash “Service Now”

So I told the mechanic to run through it and address everything that needed doing.

A few pics.....

Dirty underside.

https://i294.photobucket.com/albums/...pstdehbdnl.jpg

Rear brakes

https://i294.photobucket.com/albums/...psjuibujv3.jpg

Not good

https://i294.photobucket.com/albums/...psnji26zut.jpg

Front end

https://i294.photobucket.com/albums/...psju7vlhgv.jpg

https://i294.photobucket.com/albums/...pseetfpgvf.jpg

Front pads.....

https://i294.photobucket.com/albums/...pszav08qjb.jpg

So new discs, pads fitted all the way around.

https://i294.photobucket.com/albums/...psi7cudaje.jpg


Digging around further, Ivan came up with some interesting surprises.....

Shock retaining washers and nuts......

Old and new.

https://i294.photobucket.com/albums/...pshzwukr0n.jpg

Yup, it is dead alright.

https://i294.photobucket.com/albums/...psfddc3fox.jpg


Replaced and serviced parts have made the drive feel much smoother.

Not cheap, and actually more than I would have liked to spend, but now I seem to have a decent car again.

Oh, and lastly....

Dennis in St Louis sent through a pic of his service station.

Almost a Christmas card pic for men.


https://i294.photobucket.com/albums/...psv5xosw4e.jpg


.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Glad you got the brakes squared away. Normally one of the first things I always address on a "new" (well new to me) vehicle. Almost always I think I find the same condition.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

I would say that’s a sensible approach Bill.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Well, it ended quietly, with compassion and dignity.

I know not everyone cares about animals, and that’s fine too.

But the last ten years Harley has been a companion and friend to me, always a shadow and near me in the garage or wherever I was working. More dog than cat.

An aggressive oral cancer, which filled half her mouth in two weeks so that in the end she could not eat or drink.

Commando Surgery on a 15 year old was not an option.

I hope these pics make you smile as they certainly did me.

https://i294.photobucket.com/albums/...pszvyomkpf.jpg

Inspecting Prozacs contents.

https://i294.photobucket.com/albums/...psjc1chafv.jpg

https://i294.photobucket.com/albums/...psw76g76s4.jpg

A seeker sunbug for sure.

https://i294.photobucket.com/albums/...psxqasqotb.jpg

https://i294.photobucket.com/albums/...psq8nbobid.jpg

https://i294.photobucket.com/albums/...pshgb2a0h4.jpg

Forum story proof reader.Quality Control.

https://i294.photobucket.com/albums/...psplmyuqi7.jpg

Melted cat on the hottest day of summer.

https://i294.photobucket.com/albums/...psyqwh4bhu.jpg

https://i294.photobucket.com/albums/...psshx1aasa.jpg

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Really sorry to hear Rian. Had to put down one of my dogs last month, so know how it feels. RIP Harley.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Hey man, so sorry for your loss.
It seems so strange in a way that we get so attached to these creatures.
Then in another way it is not so strange at all.
Death is really an extention of life but on another plane.

Take care, bro.
Still praying for you, your bro.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Rian, so sorry to hear this. I can’t say anything to make it better but hopefully you can take a little comfort in knowing that you did the right thing and the only thing you could to help him.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Sorry to hear the news Rian.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Sorry to hear that too that you lost a friend.

Dogs sometimes feel more human to me, closer, more emotionally connected.

Harley was half dog for sure

Agreed Vince, and thank you.

She was a faithful companion for a long time, the least one can do is not being selfish.

Thanks Bill, Thank you all for your comments and PM’s

She was certainly part of my life and made sure anyone who visited here was given the security check over and then welcomed as family.

Some animals just fit in well.

And she was part of the forum, often by her own insistence, to be in cars, the wood shop, garage etc.

The house is certainly quiet without her being around me, talking, to me constantly, waking me at 5.30 for her breakfast etc.

And it will be quiet going forward.

But we get over this sort of thing.

The memories and many moments of laughter she induced will stay.




Interesting to see Photophukit has killed a bunch of recent photos again.

Not sure if anyone else has experienced that.



Almost the weekend.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Hi Rian I am very sorry to hear about Harley . our fur family's bring us special times that we will all ways remember them by. each one has it's own special place in our heart.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

All are unique for sure.

Some just more than others ;)


Photophukit seems to have a mind of its own right now.

Nicola sent a few more pics of Harley that I suspect many of you will enjoy too.

https://i294.photobucket.com/albums/...psbxjwchqc.jpg

Loved a fire, also fearless of them, like with power tools.


https://i294.photobucket.com/albums/...psk2s1ilcv.jpg

Surfing the web.

https://i294.photobucket.com/albums/...psbqwh3ngs.jpg

https://i294.photobucket.com/albums/...pskzlfx2m0.jpg

https://i294.photobucket.com/albums/...psjhzhqozh.jpg

Sweet innocent cat.

https://i294.photobucket.com/albums/...pssnfycehb.jpg


And where this story really started

December 2010 when I moved to this house and bought the Sachs Madass.

Security checked by her.

https://i294.photobucket.com/albums/...psde5tn81t.jpg


And a final good bye from Harley the Fearless.

Set up in her new job now........

A happy girl.


https://i294.photobucket.com/albums/...pslqogznen.jpg

The house has been empty for sure, and one sees her and looks for her in all the places she should be.

She will be missed,

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Earlier this week a big or important part of the “build” arrived in the post.

Microphone for the Bluetooth telephone system and radio.

Will get fitted as soon as there is a bit of decent weather and time.

https://i294.photobucket.com/albums/...ps4calij6z.jpg

More than to happen.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Had the most amazing nights sleep.....


About 9 hours in total, not even what I get after jet lag.

Then an extremely slow start, Some laundry, clearing the house a bit and lazy breakfast.

And eventually carried loads of stuff to the garage.

Started on removing the Galaxy’s wing mirror.

The cold does not help, and neither does the fact that I have no idea how it’s all put together.

So rather than break clips or panel parts, I reassembled after a few minutes, and Torx suxx.

https://i294.photobucket.com/albums/...pstvmo3xto.jpg

And started moving the Mercedes Benz wheels into the little caravan workshop, along with an electric oil finned heater and some small sanders.

https://i294.photobucket.com/albums/...psdgyma9bd.jpg

More later.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Feeling pretty chuffed tonight.

Started with refurbishing the wheels for the Galaxy today.

Using the free two berth caravan I got and prepared in October, I have managed to prep, prime, paint and clear lacquer the wheels obverse 8 hours, which included paint drying time, and a run to go fetch another can of etch primer.

Work table.

https://i294.photobucket.com/albums/...psxfzgee6g.jpg

Hand held orbital sander made life easier.

https://i294.photobucket.com/albums/...pshuugfzmg.jpg

All the damage sanded back

https://i294.photobucket.com/albums/...psl3zdnmgv.jpg

Four wheels done.

https://i294.photobucket.com/albums/...psdnlno4o8.jpg

Ready for etch primer.

https://i294.photobucket.com/albums/...psfb6njtqv.jpg

Typically, the etch primer I had was not as much as I thought there was, so Sally and I had to run down to Chatham to get some.

https://i294.photobucket.com/albums/...pslkifquyk.jpg

Got it.

https://i294.photobucket.com/albums/...psjisxlmdu.jpg

Primer going down.

https://i294.photobucket.com/albums/...psdx2nvrxp.jpg

https://i294.photobucket.com/albums/...ps3ovqis8t.jpg

And done.

Oil heater doing it’s thing...... drying the primer while I went to make us dinner.

https://i294.photobucket.com/albums/...psqm0brpwg.jpg

Decided to give it 90 minute to dry before going back to paint the silver on.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Nice work. Looking forward to seeing the finish with the silver paint.

You get your new-new replacement center caps yet?

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Thank you Bill.

It’s interesting, that one can hardly see the difference between coats.

Waiting for caps, may have selected a supplier from China.


Part two.....

Paint and clear lacquer

Before and after primer.

https://i294.photobucket.com/albums/...psmmsfntkq.jpg

Four painted.

https://i294.photobucket.com/albums/...pselwldcw7.jpg


Clear coated

https://i294.photobucket.com/albums/...psrqq7jnpa.jpg

Rear 8.5 J’s clear coated

https://i294.photobucket.com/albums/...ps1rmbfotk.jpg

Front 7.5J’s after three coats of clear.

https://i294.photobucket.com/albums/...psr453rxyy.jpg

I will try leave them alone for a day or two to harden before taking them back for the tyres to be fitted and then fitted to the car.

Have to consider these too.......

EBay item number 163342504162


Lo Suspension - Make driving more fun!


Set of 4 Sports Lowering Springs for: FORD GALAXY 2.0, 2.3 & 1.9 TDi 1995>2006 Lowers by 35mm - a new & unused Lo Suspension branded product from losuspension.com

Are you looking for a lower ride?

Key Features
LO springs are designed specifically for your car
Your mechanic will have no trouble fitting LO springs
Compatable with your original shock absorbers
Your car will have a much sportier stance
Your car will have more responsive handling
You will have more confidence when cornering
Your car will have less body roll
LO springs are TUV approved
LO springs have a 12 month warranty

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Hot Rodder for Life!:metal::ito:

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

:metal::metal::metal:


Got some pics from my friend Stanislav in Siberia, including this one.

Feels like spring he said.

Not yet the -38’C that they had last year.

https://i294.photobucket.com/albums/...psytuqmk5y.jpg

Back to lowering the Galaxy.

Bill.......

Thank you.

https://i294.photobucket.com/albums/...psaxduuoax.jpg

Maybe not that hardcore.

Had some feedback on these lowering springs, seems they may not quite deliver as advertised.

Anyone else got experience with them?

https://i294.photobucket.com/albums/...ps6kp0vhhm.jpg

Wheels finally put the “workshop” and into the back of the Galaxy.

Final finish.

https://i294.photobucket.com/albums/...pskrgkqne1.jpg

Looking forward to getting these fitted up with tyres and on the van.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Ahhhh Christmas break. Many parts blasted and etch primed.

Plus Photophukit playing up continually

So not much to show.

On Friday I realised that Murphy’s law meant one would run out of gas on a Saturday evening or some similar inconvenient time.

So I called to order in a spare bottle of 5% Argon/CO2

Paying a bottle deposit and gas content came to £94.00 and included home delivery on Saturday morning

http://i294.photobucket.com/albums/m...psbxvnaxpj.jpg

Service worth paying for.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Last bit about Christmas

I prefer a BBQ to Turkey at Christmas

Thankfully Sally and her son Ryan agreed.

http://i294.photobucket.com/albums/m...psjuepajje.jpg

So.... only coleslaw as token vegetable

The rest: Lamb Kofte Kebabs, lamb ribs, pork belly, Sweet Tai Chilli Chicken thighs, German Bratwurst, glazed Texas Pork Chops.

Yup.

http://i294.photobucket.com/albums/m...psva402lja.jpg

Merry Christmas it certainly was.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Christmas Eve Day.

Good time as any to start with the smallest Cut and Weld job identified so far.

I will be over describing for many of you.
But if like me, you have not done this before it may be helpful or not?

So off to the “caraworkshop”

Move tools into the “shed” and find some donor steel.

Built this 100kg plus mobile work station in 2015. So moved it closer.

Used it a few times since.

http://i294.photobucket.com/albums/m...psz0evxsz4.jpg

Straight in with my trusty cardboard template and scissors

Donor steel. 1965 C10 cab.

As @PaulY said, if I use enough off this one I may need to add a new V5c registration document

http://i294.photobucket.com/albums/m...psxhis5o2j.jpg

Piece is bigger than just the holes. Loads of old dents to cut out as well.

http://i294.photobucket.com/albums/m...psukm7rfub.jpg

First fold to 90’ then back to lay the base crease.
Followed by opposite bend to complete the peak.

http://i294.photobucket.com/albums/m...pslhzgzd1u.jpg

Top and bottom curves added, they do differ a lot.

http://i294.photobucket.com/albums/m...psjpn2kohg.jpg

http://i294.photobucket.com/albums/m...psrb9sfpbb.jpg


Next up would be tracing the replacement panel onto the front panel

http://i294.photobucket.com/albums/m...psu1c84tvg.jpg

Followed by cutting the bad metal out.

Coffee break first.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

At this point I thought it wise to clean up my welding mask in preparation for the bit of welding coming up.

Pooop.

Auto dimming non functional despite this mask having had very little use to date.

Tried the various setting buttons to no avail.

Then tried opening it to see if batteries can be replaced as I always keep a large selection of batteries

Nope.

Sealed unit.

Youtube.... ??

Success !!

But pretty clear that its a difficult task to try work around the sealed unit etc.

So I tried....... FAILED.

REASSEMBLED and graffitied it as a POS.

http://i294.photobucket.com/albums/m...psctccaqwg.jpg

But would have to use it anyway as shops were shutting etc.

Have to wait for Saturday as shops are shut.

Burger !!!

http://i294.photobucket.com/albums/m...ps4dst4bn1.jpg

Have pencilled in getting one of these

http://i294.photobucket.com/albums/m...pszjv9hnpi.jpg


Later.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

So.........

Cat Stevens sang “The first cut is the deepest”

Not sure if its that relevant to this truck, but once marked out, I fitted a new cutting disc and set to work cautiously

http://i294.photobucket.com/albums/m...psxgeewbnc.jpg

Cut through.

Then used a file to tidy up the corners and a flap disc to clean the etch primer away.

http://i294.photobucket.com/albums/m...ps2hosdjvg.jpg

More fettling and fine tuning needed.

http://i294.photobucket.com/albums/m...pslfrtcfoc.jpg

Everything takes time.

But got it done.

http://i294.photobucket.com/albums/m...psv9mhcih1.jpg

Then earthed up the front panel after practicing and lowering the power feed but increasing wire speed on some of the scrap metal.
Started tacking one spot at a time to prevent warping.

http://i294.photobucket.com/albums/m...psqdkfkmxd.jpg

Ground back.

Holes filled, dents mostly gone, needs a skim of filler eventually

http://i294.photobucket.com/albums/m...psl9j6gv6l.jpg

Etch primer both sides.

http://i294.photobucket.com/albums/m...psubjbsbah.jpg

And all of this just to remove this bit of mess.

http://i294.photobucket.com/albums/m...psbfrhue0q.jpg

So that was day one.

Two hours in total, start to finish.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Dude, you are THE MAN, great job.
You just jumped off in there and got'er done.
Looks great too. Your caravan workshop is really a nice addition to your work space.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Nice work Rian!! :metal:

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

hi Rian happy holidays , nice job on the rust repair !! great to see progress on the 66 . your resto on the new van wheels looks great too !! .

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Looks great Rian .

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Thank you Vince.

It has delivered as well as possible

Warm, dry, organised

Good enough, and better than before.

Thanks Jim, Happy Holidays to you and yours as well.

Wheels came out well.

Hi John, thanks buddy.

Happy too.


So we were out early-ish to go swap some Christmas presents for the correct size.

And to pick up a new welding helmet at Tool Station.

I had previously read up on specifications and found that the £10.00 difference between two lower price helmets equated to one sensor vs four. Quicker response time. Exchangeable batteries etc.

So you get what you pay for in this game.

I bought the SiP welding mask without stickers. (Watch this space)

http://i294.photobucket.com/albums/m...psq0m09qpd.jpg

Spec sheet.

http://i294.photobucket.com/albums/m...psjrvlhbwe.jpg

I guess the next step is going to be gingerly making my way toward the garage and choosing what repair to start on next.

It may be partly dictated by the repair steel availability

More later.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

That looks like a good choice for a helmet. Your right about getting what you pay for!

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Absolutely

Works real well.

Spent less than two hours down in the shop today.

Had some stuff to deal with.

First job was to correct part of yesterday’s front panel repair, adding about 15mm weld from behind on the crest.

https://i294.photobucket.com/albums/...psroqrrwy0.jpg

Dressed back.

https://i294.photobucket.com/albums/...psx2thb9fx.jpg

Primed.

https://i294.photobucket.com/albums/...psizgwuyon.jpg

Packed away, along with the radiator panel and inner fenders.

https://i294.photobucket.com/albums/...psqsu6l2mx.jpg

.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Despite all sorts of good intentions, I managed less than 2 hours in the shed today.

Part was correcting my previous weld.

Then on to a few holes in the drivers side door.

https://i294.photobucket.com/albums/...psrga2vi49.jpg

Looking at the original drivers side door, specifically where the mirror was mounted, vs the new passenger door I got, that obviously used to have convoy mirrors

So I needed to ensure I welded up all the right holes.

Using both the new mirror stalk and measurements from my old door.

It has some work to do too.

https://i294.photobucket.com/albums/...pswuzjvtrg.jpg

https://i294.photobucket.com/albums/...psro80htvj.jpg

https://i294.photobucket.com/albums/...pskw4eemmu.jpg

Of course it has some interesting inverse dents, but nothing a hammer and dolly could not sort, with caution.

https://i294.photobucket.com/albums/...ps7zois2th.jpg

Convoy mirror mounting points.

Prepped.

https://i294.photobucket.com/albums/...psqlo2dcwr.jpg

Adjustable heat sink tool.

Copper pipe.

https://i294.photobucket.com/albums/...pstnc2a6dt.jpg

Holes plugged.

https://i294.photobucket.com/albums/...psf9dalwn5.jpg

Worked back.

https://i294.photobucket.com/albums/...pszyzvsvp0.jpg

Etch Primer added.

. https://i294.photobucket.com/albums/...psh74poj08.jpg

At this point I closed shop.

Next job will be cutting some rust from the door skin and replacing with fresh metal.

Done.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

:metal:

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Amazing how it takes time to do every action.

But happy to be back on it again

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Another copy and paste on here with a couple of video clip links around metal working.

I was asked the question by a mate, and am pretty certain I have not covered it fully, so happy for anyone else to add in more to enhance the response as a resource for anyone else, who like me learns as they go along.





OK. So half your reply lies in this video.

https://youtu.be/0Iik1ftVGXI


And then some more here.


https://youtu.be/qBJwngEimZU


Half or more than half the holes and repairs on this truck will be to older holes that may have been worked before, leaving the metal thin and tired.

The copper is essentially a non stick surface where the new weld (molten steel) is laid down in order to either fill, or repair, join fresh metal.

Sheet metal is actually quite thin and the first thing that happens is that you blow holes through it, making the hole bigger when a welders amps, wire feed is not set up right. Different jobs take different settings, like most things in life.

Where old rust has eaten at the steel, it becomes fragile, like lace, with holes mixed in with thin, compromised steel in between which mostly cannot be welded up.

So you cut away the dead metal, and make and shape up a patch and weld it back in.

When heated to melting point by the weld, the metal expands and pushes (WARPS) surrounding metal.

The copper removes some of the heat fast.

I also have a copper plate, 120mm X 50mm X 6mm used for larger flat sections. As well as some bronze “round bar” part of an old shaft.

The flattened copper pipe can be shaped and bent to fit in spaces like a door window frame etc as shown.

Many places (because rust happens in tight spots often as slow evaporation and crud collection ) you cannot get in with a heat sink, so a wet rag can work, or small repeated spot welds work better.

Hence it often taking time, a lot of time to do what seems like a small job.

Practice helps with speed too. But making a shaped panel or patch adds time.

Once welded, you need to grind back, inspect, and weld again if holes appear where you did not quite get penetration or filling.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Glad to see you back on it . Repair looks good. Of course I will have to come and inspect it

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Of course you will inspect it......

I just hope to pass muster :mm:






Another typical holiday start,

Only got out the house by about 11.15 or so.

No regrets though.

So this was today’s task.......

Weld up the small hole to the left once it stopped running away from me, as it was going to be paper thin up to a point.....

Where the point ended up being, that was the question.

https://i294.photobucket.com/albums/...ps36iebayj.jpg


Thought I would also just for the sake of illustration for those unfamiliar or not initiated in Mig welding, share a few of my heat sink tools.

https://i294.photobucket.com/albums/...pshcal0sbe.jpg

And another important tool(s)

The grinder.

I keep three on standby, all differently set up, one with a 1mm cutting disc, one with a 5mm grinding disc, and a flap disc for finishing off.

https://i294.photobucket.com/albums/...pslcnx1kbr.jpg

So back to the patch, I calculated that a 50mm X 50mm patch would cover the weakness and holes.

Keep in mind, this is my very good California door for the passenger side.

It still has work on the inside too, dents and a lace finish of rust on the bottom cup.

So patch ready with a very gentle curve bent into it.

The door bottom corner has sustained some damage before at some point, resulting in a somewhat bent corner, and also some very mild extended dents on the door skin, shown later.

https://i294.photobucket.com/albums/...psanswjyzl.jpg

Marked out for cutting, xx and x marks to maintain correct orientation on gentle curve. Note existing dents next to previous weld.

https://i294.photobucket.com/albums/...psd6afw0fc.jpg

And CUT !!!

https://i294.photobucket.com/albums/...psexwsiwfd.jpg

Lift

https://i294.photobucket.com/albums/...pswgeju5w9.jpg

Contrast

https://i294.photobucket.com/albums/...psyhego0fv.jpg

Result.

https://i294.photobucket.com/albums/...psxhtborkm.jpg

It’s a Boy !!

https://i294.photobucket.com/albums/...pszou32axx.jpg

Part one done,

Coffee time.

Re: Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!
 

Just to illustrate how time slips between your fingers like sand on a hot summers day on the beach the next step was to go dig out the garage vacuum cleaner.

Residual grit from the media blasting down in the bottom seam of the door plus grinder dust needed to be removed.

Followed by fine tuning the fit of the patch into the now gaping hole in my door.

Nice and it actually was.

https://i294.photobucket.com/albums/...psxhtborkm.jpg

Using my magical welding magnets, I tacked the corners and then centres.

In order to prevent warping I carried on slowly, allowing it to cool between sessions.

https://i294.photobucket.com/albums/...pspjjyeu6i.jpg

During this time my long suffering photographer got in from work.

So I gave her a POS mask to wear while trying to get a pic of me striking an arc.

https://i294.photobucket.com/albums/...psgizrma2o.jpg

Success.

https://i294.photobucket.com/albums/...psmhjkcsxu.jpg

After all the welding, I ground the welds flatter, then proceeded with a hammer and dolly, trying to reshape the corner which had been damaged at some point in the past.

https://i294.photobucket.com/albums/...pslfhc3gii.jpg

Eventually, etch primer and done.

https://i294.photobucket.com/albums/...psznwfu2tb.jpg

Hardly visible, and I suspect it will be a skim of filler job eventually, but two long skinny dents from the past.

https://i294.photobucket.com/albums/...ps1egi19hr.jpg


That concludes the welding on the outside of the passenger door.

Next job will be the rust on the insides of the door.

Time for a rum and Pepsi Max now.