Re: 55 Wagon Progress
 

Huh blind hole spotter who knew, definitely not me, learn so many cool little tricks.

Re: 55 Wagon Progress
 

I was blocking out the tailgate the other day and had a "halo" effect appear in the epoxy, shown below just to the right of the latch hole. This has a light skim of Evercoat 416 beneath the epoxy in that area. It was nice and flat while in bare metal, after spraying epoxy, after blocking the Evercoat/ before spraying the last coat of epoxy. I was baffled at what would cause such a nicely formed circle in the paint...


http://i5.photobucket.com/albums/y16...ure%202939.jpg

http://i5.photobucket.com/albums/y16...ure%202940.jpg

http://i5.photobucket.com/albums/y16...ure%202942.jpg

http://i5.photobucket.com/albums/y16...ure%202944.jpg


Even scratched the area to see if there was any softness to the Evercoat, but no..

http://i5.photobucket.com/albums/y16...ure%202947.jpg


Here's the panel in bare steel before paint and after first coat of epoxy...


http://i5.photobucket.com/albums/y16...ure%202350.jpg


http://i5.photobucket.com/albums/y16...ure%202366.jpg


No dings, or defects otherwise seen. I had posted a query on the SPI forum to see if anyone had ever run into this. I don't know why I didn't think of this first, but it was suggested to: 1) look inside 2) only time this type of defect had been seen was dropping screwdriver inside door and left similar mark on outside of door bottom after sanding.


So in full investigative mode, I first measured the distance of the defect from the turn latch hole..


The Halo is approx. 3" away from the handle hole..


http://i5.photobucket.com/albums/y16...ure%202982.jpg


Measuring that distance on the inside shows.....oh wait....what's that bare metal?


http://i5.photobucket.com/albums/y16...ure%202983.jpg


http://i5.photobucket.com/albums/y16...ure%202984.jpg


As soon as I saw this I realized there had only been one thing inside that could have caused it... the painting fixture we made..


http://i5.photobucket.com/albums/y16...ure%202985.jpg


This was made to hold the tail gate in correct alignment as on the car for painting. I had radiused the lower bar but failed to do so on the top one. A check of the skin with body sweeps shows that a #15 sweep is about correct, so it was used to verify some relief grinding on the top bar...


http://i5.photobucket.com/albums/y16...ure%202986.jpg


http://i5.photobucket.com/albums/y16...ure%202987.jpg


http://i5.photobucket.com/albums/y16...ure%202988.jpg


As added insurance, some truck cap gasket seal was added to further isolate the issue on both top and bottom bar....


http://i5.photobucket.com/albums/y16...ure%202989.jpg


http://i5.photobucket.com/albums/y16...ure%202990.jpg


On a positive note, glad to find this issue in the primer stage......

But let's back up a second and look at this picture, it should have been my red flag. Where the second mark to the left in the picture was not as round, looking at it now does show a rather symmetrical device was causing this..


http://i5.photobucket.com/albums/y16...ure%202940.jpg



So please use my lesson in dumassery to prevent a similar occurrence. :lol:

Re: 55 Wagon Progress
 

Another job in the shop, here's one of the downfalls of the insulation blankets the factory used above exhaust systems...


http://i5.photobucket.com/albums/y16...ure%202991.jpg


http://i5.photobucket.com/albums/y16...ure%202992.jpg


http://i5.photobucket.com/albums/y16...ure%202993.jpg


Nice moisture traps and rust generators. All the used beds found either had similar rust issues or the lower quarters rounded under where the salvage yards had removed them and set them down on the ground. So we went back to the local dealer and ordered the bed floor and new cross members. We have a couple cross members that still haven't arrived, but we can get started in prepping for epoxy primer on the parts we do have..

Scuffing up the floor using 400 grit. Here's the new apprentice for this job, my niece Katie. (her truck) She's not afraid of work and needed little instruction.


http://i5.photobucket.com/albums/y16...ure%202997.jpg


All scuffed, now to wait on the cross members to come in..


http://i5.photobucket.com/albums/y16...ure%203002.jpg


Meanwhile Kyle and I have continued blocking body parts for another dose of epoxy...


http://i5.photobucket.com/albums/y16...ure%202996.jpg


http://i5.photobucket.com/albums/y16...ure%202998.jpg


http://i5.photobucket.com/albums/y16...ure%203003.jpg


http://i5.photobucket.com/albums/y16...ure%203000.jpg

Re: 55 Wagon Progress
 

So if your name starts with a K you can hang out in the shop with Robert and have fun while learning.

Re: 55 Wagon Progress
 

Been a while but just caught up. Nice work aws always!

Re: 55 Wagon Progress
 

Tons of great work, cool ideas and useful tools. Thanks again for continuing to share.

Re: 55 Wagon Progress
 

It would seem so.... :lol:

Thanks for the comments guys!



Got some more SPI Epoxy sprayed, here's the parts for Katie's truck that she prepped...


http://i5.photobucket.com/albums/y16...ure%203010.jpg


http://i5.photobucket.com/albums/y16...ure%203011.jpg


....and some more on the wagon parts....


http://i5.photobucket.com/albums/y16...ure%203013.jpg


http://i5.photobucket.com/albums/y16...ure%203014.jpg


http://i5.photobucket.com/albums/y16...ure%203015.jpg


http://i5.photobucket.com/albums/y16...ure%203016.jpg


http://i5.photobucket.com/albums/y16...ure%203017.jpg

Re: 55 Wagon Progress
 

Parts look good...Jim

Re: 55 Wagon Progress
 

Thanks Jim!


Tonight's post offers some blocking pointers.

We had already done a couple sessions of priming/blocking the door across to the quarter and to the fender, all installed on the car. After this, more primer and put a perimeter of tape on the door skin. Now block separately, and the tape allows you to block the door and keep off the edge to prevent losing your match to the fender/quarter.


http://i5.photobucket.com/albums/y16...ure%203031.jpg


I don't stick with 45* angles, if you want to keep a long direction flat, you need the long block to better follow that direction. So change up to some sharper angles, about 30* off the long direction every now and then. Work one end to the other, consistent spacing, consistent angle, end to end. Then alternate to passes in the opposite direction.


Once done, and the inner part is good and blocked, now remove the tape and GENTLY block to the edge, taking care to not pull down at the edge and round things back off again. Whatever hand is holding the block make sure it is minimal pressure and stays on the door skin. In other words, no pressure pulling down past the edge.


http://i5.photobucket.com/albums/y16...ure%203034.jpg


One other point, to keep the inner end of the sanding block from sanding out all your hard work in the center of the door, put a wrap of tape around the end of the sanding block that is towards the center of the door. This helps that end to glide across the center of the door without cutting primer there.


http://i5.photobucket.com/albums/y16...ure%203033.jpg


http://i5.photobucket.com/albums/y16...ure%203036.jpg


Now to show the importance of the long board..


We had done some blocking with the 27" AFS and seemed to have two high spots with a low in the middle of the door..

Note the high areas marked by the green tape...


http://i5.photobucket.com/albums/y16...ure%203024.jpg


http://i5.photobucket.com/albums/y16...ure%203026.jpg


Now we can see that as the sander is moved to the left, the left portion of the AFS is over the high spot on the left, and a bit more movement and the right portion of the AFS will start dropping into the low void. Effectively, this is still cutting material out of the low, keeping it low.


http://i5.photobucket.com/albums/y16...ure%203028.jpg


Looking at the next size up, a 36" AFS....


http://i5.photobucket.com/albums/y16...ure%203019.jpg


http://i5.photobucket.com/albums/y16...ure%203020.jpg


Here we can see this one does a much better job of spanning the high spots and staying up on top, for a more effective job of knocking down the highs and leaving the low in the center alone...


http://i5.photobucket.com/albums/y16...ure%203029.jpg


After a few horizontal passes at slight angles, like so with the 36".......


http://i5.photobucket.com/albums/y16...ure%203018.jpg


We follow up with some vertical passes at slight angles with the 27".... all rods removed to better follow the contour. Then alternate back to the 36 and another horizontal session..

http://i5.photobucket.com/albums/y16...ure%203030.jpg

Re: 55 Wagon Progress
 

Nice work, wish you could do my truck next. :)

Re: 55 Wagon Progress
 

Got a 54 Divco milk truck coming in next, sorry. :lol:


Well, the shop truck has left the building..


http://i5.photobucket.com/albums/y16...ure%203040.jpg


Sold it today, now have a bit more breathing room in the shop..


http://i5.photobucket.com/albums/y16...ure%203042.jpg


http://i5.photobucket.com/albums/y16...ure%203043.jpg


.....and another dose of epoxy


http://i5.photobucket.com/albums/y16...ure%203045.jpg


http://i5.photobucket.com/albums/y16...ure%203047.jpg


http://i5.photobucket.com/albums/y16...ure%203048.jpg


http://i5.photobucket.com/albums/y16...ure%203050.jpg

Re: 55 Wagon Progress
 

So you're not using high build? Just make the filler work slick enough and then epoxy? Or does the SPI epoxy build more than other epoxies? Been wanting to try SPI epoxy...

Re: 55 Wagon Progress
 

AWESOME. You have MAD SKILLS..

Re: 55 Wagon Progress
 

John, I've found both H/K and SPI to have a decent amount of build. Not as much as spraying Slick Sand, but I'd venture a guess that SPI on SPI would have less adhesion issues and be more stable overall than mixing products.


Thanks Nasty!

Re: 55 Wagon Progress
 

That's good to know- Nason's epoxy is only good for a scratch coat. About the consistency of basecoat. Parts look fantastic.

Re: 55 Wagon Progress
 

I'm definitely going to try some SPI. We've been using Slick Sand over DPLF within the 7 day recoat window, and the SS etches into the epoxy pretty hard so adhesion hasn't been a problem. But if SPI builds enough then we could skip the SS step, at least on some areas. The one thing I really like about SS is you can get the size/shape/diameter of your edges and body lines all even since there is plenty of material to work with, especially when blocking body lines across multiple panels. But, sometimes you don't need that much of a build primer if the metal/bodywork is already close before priming. It'll be interesting to try it out, I'm always looking for anything that'll make for a better job.

Re: 55 Wagon Progress
 

If you don't want that much build, look at Evercoat G2. Same stuff, not as thick. Moves a bit easier and lays down better. I usually throw a splash of thinner in my SS to get it movin' a bit easier, as it were. I'm interested in the SPI stuff as well.

Re: 55 Wagon Progress
 

Well there has been a slight break in the updates, as I've been in Okinawa for about a month. Not to fear, Kyle has been plugging away on the wagon, it even has a floor in it, as you can see here...


http://i5.photobucket.com/albums/y16...ure%203051.jpg


http://i5.photobucket.com/albums/y16...ure%203053.jpg


He did get a quite a bit of blocking done while I was gone....


http://i5.photobucket.com/albums/y16...ure%203045.jpg


http://i5.photobucket.com/albums/y16...ure%203059.jpg


http://i5.photobucket.com/albums/y16...ure%203060.jpg


And did get some wet sanding done on a few of the interior trim pieces. Today he started on the rear floor, part of the problem with welding a flat plate is that it doesn't stay flat. The plug welds to secure the floor to the bracing beneath caused some shrinking, which resulted in the metal between bulging outward, some up, some down. Looks about like the Atlantic on a calm day.


http://i5.photobucket.com/albums/y16...ure%203054.jpg


http://i5.photobucket.com/albums/y16...ure%203056.jpg


Today, as I was going to be wet sanding, he was going to try some torch shrinking. To better make this a one person job with minimal risk of open flame, we thought to give the "electric" torch a go.


http://i5.photobucket.com/albums/y16...ure%203063.jpg


http://i5.photobucket.com/albums/y16...ure%203061.jpg


The plastic dust pan served as a tray to hold the wet rag, keeping it in closer proximity to where it was needed and attempt to limit the amount of water elsewhere. The results showed quite an improvement, and it's in need of some bumping at this point..


http://i5.photobucket.com/albums/y16...ure%203064.jpg


But alas, the gas tank is in the way, so we will likely get the body back on the rotisserie here soon in an effort to get the remaining prep prior to paint completed.

Meanwhile, I was wet sanding and couldn't find the squeegee, so a trip to the local Ace Hardware at lunch, and we had a replacement. Works well, and no metal hardware on this new one to add any scratches....


http://i5.photobucket.com/albums/y16...ure%203067.jpg


http://i5.photobucket.com/albums/y16...ure%203068.jpg


Exterior of the hood is about done...


http://i5.photobucket.com/albums/y16...ure%203069.jpg


http://i5.photobucket.com/albums/y16...ure%203070.jpg

Re: 55 Wagon Progress
 

I was just thinking today, wonder how Kyle progress was coming along, get home from work and poof there's a update.

Re: 55 Wagon Progress
 

Looks great. Was thanking you'all today when I was welding in my dash modifications, blending & bumping.

Thanks for all the helpful tips

Re: 55 Wagon Progress
 

Everything looking good, big change in the floor...Jim

Re: 55 Wagon Progress
 

The floor did come out well. Great attention to detail making it flat. Was only the rear section replaced or front to rear?

Re: 55 Wagon Progress
 

The floor has been replaced from front to rear. The flat section on the rear was a piece of 16 ga hot rolled that the owner had, and hindsight being the great educator, should have been the last thing we used. I'd do a piece of cold rolled 18 ga with bead details, and wouldn't have all this to contend with. BTW, floor has been installed for some time now, Kyle just uncovered it... :lol:

Thanks for the comments, Bomp, glad to hear some of the posts here have helped out!

Re: 55 Wagon Progress
 

The last time we removed the car from the frame we used two engine hoists, which proved to be a bit cumbersome and a pain to get the frame rolled out. So I thought to try something different, this time an engine hoist at the front, and a winch in the back. Needing an anchor point for the winch, I welded this up last night to span two of the shop's trusses from overhead....

http://i5.photobucket.com/albums/y16...ure%203071.jpg


Rear lift eyes use the tailgate hinge nut plates...


http://i5.photobucket.com/albums/y16...ure%203073.jpg


http://i5.photobucket.com/albums/y16...ure%203074.jpg


http://i5.photobucket.com/albums/y16...ure%203075.jpg


Front lifting eyes bolt to the hinge mounts on the firewall...


http://i5.photobucket.com/albums/y16...ure%203076.jpg


http://i5.photobucket.com/albums/y16...ure%203077.jpg


http://i5.photobucket.com/albums/y16...ure%203078.jpg


We have lift-off!


http://i5.photobucket.com/albums/y16...ure%203080.jpg


http://i5.photobucket.com/albums/y16...ure%203081.jpg


http://i5.photobucket.com/albums/y16...ure%203082.jpg


The frame has a bit of welds left to do and we can clean it up and get it to the powder coaters...


http://i5.photobucket.com/albums/y16...ure%203083.jpg


http://i5.photobucket.com/albums/y16...ure%203089.jpg


Dana helping out tonight...


http://i5.photobucket.com/albums/y16...ure%203084.jpg


One way to clean it out...


http://i5.photobucket.com/albums/y16...ure%203085.jpg


Here's the framework added to support the fuel tank and rear floor..


http://i5.photobucket.com/albums/y16...ure%203086.jpg


This shows how nice access is for prepping, works equally well in painting..


http://i5.photobucket.com/albums/y16...ure%203087.jpg


http://i5.photobucket.com/albums/y16...ure%203088.jpg

Re: 55 Wagon Progress
 

I've always said, where there's a will, there's a way. Nice job on the lifting. Sure makes it easy when you can flip the car the way you need it...Jim

Re: 55 Wagon Progress
 

Thanks, it does come in handy.


Todays progress, we've had to move the frame a couple times and it becomes a chore to steer, so a 1" bolt was modified with a home made steering wheel. Works well, good thing there's no weight on the front end!


http://i5.photobucket.com/albums/y16...ure%203089.jpg


http://i5.photobucket.com/albums/y16...ure%203105.jpg


http://i5.photobucket.com/albums/y16...ure%203106.jpg


http://i5.photobucket.com/albums/y16...ure%203108.jpg


....and Kyle's been busy getting the bare metal prepped for epoxy..


http://i5.photobucket.com/albums/y16...ure%203109.jpg


Picked up some stump blanks last night to have some extra stations for the upcoming metalshaping class...


http://i5.photobucket.com/albums/y16...ure%203090.jpg


This afternoon, Debarking with a draw knife...


http://i5.photobucket.com/albums/y16...ure%203095.jpg


Kyle took over as I used the chain saw to cut some to length...


http://i5.photobucket.com/albums/y16...ure%203096.jpg


This one is about all the JD bucket could stand..


http://i5.photobucket.com/albums/y16...ure%203101.jpg


http://i5.photobucket.com/albums/y16...ure%203102.jpg


http://i5.photobucket.com/albums/y16...ure%203103.jpg


....and some Talstar to take care of any remaining ant domiciles.


http://i5.photobucket.com/albums/y16...ure%203104.jpg

Re: 55 Wagon Progress
 

class there's a class when is the class

Re: 55 Wagon Progress
 

Peter Tommasini is coming to the shop for a 4 day class in October. The announcements were made on metalmeet, the class at my shop was full a little over a day after the announcement. I believe there are still openings in some of the other classes....


http://www.metalmeet.com/forum/showthread.php?t=13077

Re: 55 Wagon Progress
 

Everything about this thread just screams WIN!!

I can only shake my head in amazement.

Love the way you work the work stations. Been trying to get a decent stump from my local farmer who also sells fire wood.

Re: 55 Wagon Progress
 

E
He was in Oblong last year. Amazing talent.

Re: 55 Wagon Progress
 

So true. He will be there again this year...




We're checking this week with a local machine shop to see if we can get the body media blasted... should be a much quicker prep for the epoxy..


In the meantime, the downside to plug welds and mig welds.... cleaning up all those welds..


http://i5.photobucket.com/albums/y16...ure%203132.jpg


http://i5.photobucket.com/albums/y16...ure%203133.jpg


http://i5.photobucket.com/albums/y16...ure%203134.jpg


http://i5.photobucket.com/albums/y16...ure%203135.jpg


Kyle working on more welds..


http://i5.photobucket.com/albums/y16...ure%203136.jpg


http://i5.photobucket.com/albums/y16...ure%203138.jpg


http://i5.photobucket.com/albums/y16...ure%203139.jpg


...and to get ready for the class next week, we put all the 55 parts away in the paint booth...


http://i5.photobucket.com/albums/y16...ure%203140.jpg


http://i5.photobucket.com/albums/y16...ure%203141.jpg

Re: 55 Wagon Progress
 

Getting ready for the metal shaping class at the shop this week, picked up Peter today from the airport.

Last night Kyle and I made a pedestal for some home-made stake anvils using a couple 45 lb dumbbells and some pipe/tubing, tonight made the round-head anvil and another with a holder for press brake dies....


http://i5.photobucket.com/albums/y16...ure%203142.jpg


http://i5.photobucket.com/albums/y16...ure%203143.jpg


http://i5.photobucket.com/albums/y16...ure%203144.jpg


http://i5.photobucket.com/albums/y16...ure%203145.jpg


.....and stopped by the upholstery shop this morning to get another shot bag stitched up...


http://i5.photobucket.com/albums/y16...ure%203147.jpg


Counting the hours!

Re: 55 Wagon Progress
 

hope you have time share pics through out the class

Re: 55 Wagon Progress
 

Just caught back up again, love the progress, great work!

Re: 55 Wagon Progress
 

Hope to have daily updates! :metal:


A few of the projects showed up this evening for the class, more to come tomorrow....


http://i5.photobucket.com/albums/y16...ure%203148.jpg


http://i5.photobucket.com/albums/y16...ure%203149.jpg


http://i5.photobucket.com/albums/y16...ure%203152.jpg


http://i5.photobucket.com/albums/y16...ure%203158.jpg


One of the attendees brought a CP hammer for us to use...


http://i5.photobucket.com/albums/y16...ure%203159.jpg


http://i5.photobucket.com/albums/y16...ure%203157.jpg


I'm going to have to get Peter here more often, forces me to clean up the place!


http://i5.photobucket.com/albums/y16...ure%203151.jpg


http://i5.photobucket.com/albums/y16...ure%203154.jpg


http://i5.photobucket.com/albums/y16...ure%203153.jpg

Re: 55 Wagon Progress
 

Re: 55 Wagon Progress
 

Here are some of the highlights of today's class....

Peter shows how to prepare a stump for shrinking....


http://i5.photobucket.com/albums/y16...ure%203164.jpg


http://i5.photobucket.com/albums/y16...ure%203167.jpg


http://i5.photobucket.com/albums/y16...ure%203168.jpg


http://i5.photobucket.com/albums/y16...ure%203169.jpg


Discussing weld location in panel forming....


http://i5.photobucket.com/albums/y16...ure%203170.jpg


http://i5.photobucket.com/albums/y16...ure%203172.jpg


Using magnets to hold a paper pattern for layout....


http://i5.photobucket.com/albums/y16...ure%203177.jpg


http://i5.photobucket.com/albums/y16...ure%203180.jpg


http://i5.photobucket.com/albums/y16...ure%203181.jpg


http://i5.photobucket.com/albums/y16...ure%203183.jpg


http://i5.photobucket.com/albums/y16...ure%203185.jpg


Wheeling, tuck shrinking and annealing aluminum sheet...


http://i5.photobucket.com/albums/y16...ure%203190.jpg


http://i5.photobucket.com/albums/y16...ure%203192.jpg


http://i5.photobucket.com/albums/y16...ure%203196.jpg


http://i5.photobucket.com/albums/y16...ure%203197.jpg


Capturing the tuck and shrinking on aluminum sheet


http://i5.photobucket.com/albums/y16...ure%203201.jpg


http://i5.photobucket.com/albums/y16...ure%203202.jpg


http://i5.photobucket.com/albums/y16...ure%203203.jpg


http://i5.photobucket.com/albums/y16...ure%203204.jpg


http://i5.photobucket.com/albums/y16...ure%203205.jpg


http://i5.photobucket.com/albums/y16...ure%203206.jpg


Blocking and wheeling our 19 gauge steel fender panel...


http://i5.photobucket.com/albums/y16...ure%203208.jpg


http://i5.photobucket.com/albums/y16...ure%203209.jpg


Forming the rear corner for a Model A..


http://i5.photobucket.com/albums/y16...ure%203222.jpg


http://i5.photobucket.com/albums/y16...ure%203226.jpg


http://i5.photobucket.com/albums/y16...ure%203231.jpg


http://i5.photobucket.com/albums/y16...ure%203232.jpg


Blocking on the sand bags and shrinking on the stump....


http://i5.photobucket.com/albums/y16...ure%203224.jpg


http://i5.photobucket.com/albums/y16...ure%203225.jpg


http://i5.photobucket.com/albums/y16...ure%203229.jpg


http://i5.photobucket.com/albums/y16...ure%203223.jpg


Wheeling....


http://i5.photobucket.com/albums/y16...ure%203230.jpg

Re: 55 Wagon Progress
 

Robert, thanks for posting, wish I were there...Jim

Re: 55 Wagon Progress
 

That would have been an awesome class to be in. Looks like they've all learned some very valuable lessons. I echo Jim's sentiment... Wish I were there.

Re: 55 Wagon Progress
 

Thanks for posting the pics.
Truly a great learning experience.