Re: 55 Wagon Progress
That quarter is already looking good...Jim
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Re: 55 Wagon Progress
Thanks for the info and pics.
Looks like everyone was having a good learning experience, hope the thumb heals quickly. |
Re: 55 Wagon Progress
Thanks guys!
Project updates for todays class: Wiring top edge of the copper trash can.. http://i5.photobucket.com/albums/y16...ure%203314.jpg http://i5.photobucket.com/albums/y16...ure%203315.jpg http://i5.photobucket.com/albums/y16...ure%203316.jpg http://i5.photobucket.com/albums/y16...ure%203329.jpg http://i5.photobucket.com/albums/y16...ure%203331.jpg http://i5.photobucket.com/albums/y16...ure%203346.jpg http://i5.photobucket.com/albums/y16...ure%203327.jpg Roadster quarter, making dies for the upper bead detail.... http://i5.photobucket.com/albums/y16...ure%203317.jpg http://i5.photobucket.com/albums/y16...ure%203318.jpg http://i5.photobucket.com/albums/y16...ure%203319.jpg http://i5.photobucket.com/albums/y16...ure%203320.jpg Sharpening the crease http://i5.photobucket.com/albums/y16...ure%203324.jpg http://i5.photobucket.com/albums/y16...ure%203338.jpg A bit of shrinking.... http://i5.photobucket.com/albums/y16...ure%203360.jpg Test fit... http://i5.photobucket.com/albums/y16...ure%203366.jpg http://i5.photobucket.com/albums/y16...ure%203384.jpg Marking for trimming the wheel opening... http://i5.photobucket.com/albums/y16...ure%203406.jpg http://i5.photobucket.com/albums/y16...ure%203408.jpg Inside radius backstop http://i5.photobucket.com/albums/y16...ure%203417.jpg http://i5.photobucket.com/albums/y16...ure%203418.jpg Scooter fender... http://i5.photobucket.com/albums/y16...ure%203328.jpg Trimming... http://i5.photobucket.com/albums/y16...ure%203395.jpg http://i5.photobucket.com/albums/y16...ure%203399.jpg http://i5.photobucket.com/albums/y16...ure%203402.jpg Prepping for Sport Coupe door skin removal http://i5.photobucket.com/albums/y16...ure%203410.jpg http://i5.photobucket.com/albums/y16...ure%203412.jpg http://i5.photobucket.com/albums/y16...ure%203416.jpg We took a short break for a Maryland treat... http://i5.photobucket.com/albums/y16...ure%203419.jpg http://i5.photobucket.com/albums/y16...ure%203421.jpg of course, using only the correct utensils.... http://i5.photobucket.com/albums/y16...ure%203423.jpg http://i5.photobucket.com/albums/y16...ure%203424.jpg Blocking the top section of the roadster quarter..... http://i5.photobucket.com/albums/y16...ure%203428.jpg http://i5.photobucket.com/albums/y16...ure%203437.jpg http://i5.photobucket.com/albums/y16...ure%203438.jpg |
Re: 55 Wagon Progress
Nice, that stuff takes years to master.
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Re: 55 Wagon Progress
Final update of the class, pictures from yesterday.
Wheeling door skin for a sport coupe: http://i5.photobucket.com/albums/y16...ure%203442.jpg http://i5.photobucket.com/albums/y16...ure%203443.jpg http://i5.photobucket.com/albums/y16...ure%203449.jpg Annealing copper wire to use as rivets: http://i5.photobucket.com/albums/y16...ure%203451.jpg http://i5.photobucket.com/albums/y16...ure%203466.jpg http://i5.photobucket.com/albums/y16...ure%203467.jpg http://i5.photobucket.com/albums/y16...ure%203465.jpg Cover plate for military vehicle: http://i5.photobucket.com/albums/y16...ure%203474.jpg Paper pattern http://i5.photobucket.com/albums/y16...ure%203475.jpg http://i5.photobucket.com/albums/y16...ure%203494.jpg http://i5.photobucket.com/albums/y16...ure%203517.jpg Tuck shrinking on post dolly http://i5.photobucket.com/albums/y16...ure%203452.jpg http://i5.photobucket.com/albums/y16...ure%203453.jpg Forming upper quarter reverse http://i5.photobucket.com/albums/y16...ure%203457.jpg http://i5.photobucket.com/albums/y16...ure%203458.jpg http://i5.photobucket.com/albums/y16...ure%203461.jpg http://i5.photobucket.com/albums/y16...ure%203462.jpg Wheel opening bead detail added http://i5.photobucket.com/albums/y16...ure%203478.jpg http://i5.photobucket.com/albums/y16...ure%203479.jpg http://i5.photobucket.com/albums/y16...ure%203481.jpg Tipping flange with vise grips with jaws that have been smoothed... http://i5.photobucket.com/albums/y16...ure%203482.jpg Stretching http://i5.photobucket.com/albums/y16...ure%203484.jpg http://i5.photobucket.com/albums/y16...ure%203485.jpg http://i5.photobucket.com/albums/y16...ure%203495.jpg http://i5.photobucket.com/albums/y16...ure%203496.jpg http://i5.photobucket.com/albums/y16...ure%203497.jpg http://i5.photobucket.com/albums/y16...ure%203498.jpg http://i5.photobucket.com/albums/y16...ure%203501.jpg http://i5.photobucket.com/albums/y16...ure%203510.jpg http://i5.photobucket.com/albums/y16...ure%203511.jpg Here's a video of Peter demonstrating lead loading aluminum: https://youtu.be/MSfK9XhnLeM Loading stumps for the journey to their new home.. http://i5.photobucket.com/albums/y16...ure%203512.jpg http://i5.photobucket.com/albums/y16...ure%203513.jpg http://i5.photobucket.com/albums/y16...ure%203514.jpg This class has been a blast, Peter is a wealth of knowledge and experience, and we are honored to have him share and pass this on to others. Anxiously looking forward to next year! |
Re: 55 Wagon Progress
Thanks for the pics and the vid.
Amazing |
Re: 55 Wagon Progress
Really glad to look at pics and the video, thanks...Jim
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Re: 55 Wagon Progress
thanks guys!
Finishing up the scooter fender.., http://i5.photobucket.com/albums/y16..._191425724.jpg Marked for trimming... http://i5.photobucket.com/albums/y16...ure%203522.jpg http://i5.photobucket.com/albums/y16...ure%203523.jpg http://i5.photobucket.com/albums/y16...ure%203524.jpg Tipping wheel to set the side flange.... http://i5.photobucket.com/albums/y16...ure%203525.jpg http://i5.photobucket.com/albums/y16...ure%203526.jpg http://i5.photobucket.com/albums/y16...ure%203527.jpg Profile comparison, front to rear... http://i5.photobucket.com/albums/y16...ure%203530.jpg http://i5.photobucket.com/albums/y16...ure%203529.jpg .....and side to side... http://i5.photobucket.com/albums/y16...ure%203531.jpg http://i5.photobucket.com/albums/y16...ure%203532.jpg about ready for shipping to AZ..... http://i5.photobucket.com/albums/y16...ure%203534.jpg .... and Kyle is dressing some welds and weld touch up to get the body ready for media blasting... http://i5.photobucket.com/albums/y16...ure%203519.jpg http://i5.photobucket.com/albums/y16...ure%203521.jpg Hey. you can still walk in this place... http://i5.photobucket.com/albums/y16...ure%203520.jpg |
Re: 55 Wagon Progress
Fender turned out great...Jim
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Re: 55 Wagon Progress
Thanks Jim!
Not much to show, still working on grinding welds and filling pin holes... A good testament to using Tig or O/A welding ;) Also welded up/shaved the upper firewall seam.... http://i5.photobucket.com/albums/y16...ure%203535.jpg http://i5.photobucket.com/albums/y16...ure%203536.jpg Lesson for this evening is to watch welding around stuff mounted JUST BEHIND the firewall! :banghead: http://i5.photobucket.com/albums/y16...ure%203538.jpg |
Re: 55 Wagon Progress
Great stuff. Wish I was there.
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Re: 55 Wagon Progress
Well, more welding, grinding, and then we decided to give the roof insulation removal a try. Picked a spot and dumped on some lacquer thinner, which softened it up nicely and then made a sticky mess. So we put the putty knives aside and tried the paint scrapers..... without solvents. Dry removal was definitely better...
http://i5.photobucket.com/albums/y16...ure%203539.jpg http://i5.photobucket.com/albums/y16...ure%203541.jpg http://i5.photobucket.com/albums/y16...ure%203543.jpg http://i5.photobucket.com/albums/y16...ure%203542.jpg Also got another shipment of shirts in from Bonehead Graphics... http://i5.photobucket.com/albums/y16...ure%203547.jpg and promised the owner a modified set of spot welder tips to tackle his own wagon roof repairs... http://i5.photobucket.com/albums/y16...ure%203545.jpg http://i5.photobucket.com/albums/y16...ure%203546.jpg http://i5.photobucket.com/albums/y16...ure%203548.jpg |
Re: 55 Wagon Progress
Well time to finish up Randy's scooter fender(s). The original (rear) had been loose at some point as the fender mounting holes were nice and elongated from flopping around. So I'll get them filled in and Randy will need to match drill them to the frame..
http://i5.photobucket.com/albums/y16...ure%203549.jpg http://i5.photobucket.com/albums/y16...ure%203550.jpg Use the right tools for the job :headscrat http://i5.photobucket.com/albums/y16...ure%203553.jpg After marking, when cutting out such a small piece I like to leave a "handle" until the very end.. http://i5.photobucket.com/albums/y16...ure%203554.jpg http://i5.photobucket.com/albums/y16...ure%203555.jpg ....gives you something to hold onto while fine tuning the fit http://i5.photobucket.com/albums/y16...ure%203556.jpg Nice and snug.... http://i5.photobucket.com/albums/y16...ure%203558.jpg Tacking in the filler piece... http://i5.photobucket.com/albums/y16...ure%203560.jpg http://i5.photobucket.com/albums/y16...ure%203559.jpg http://i5.photobucket.com/albums/y16...ure%203561.jpg http://i5.photobucket.com/albums/y16...ure%203563.jpg http://i5.photobucket.com/albums/y16...ure%203565.jpg Next was to trim a nice radius on the front and back ends of the new front fender.... http://i5.photobucket.com/albums/y16...ure%203567.jpg http://i5.photobucket.com/albums/y16...ure%203569.jpg Last on the list, the forming process with the old fender left some "pie crust" edging, as seen here and in an original photo... http://i5.photobucket.com/albums/y16...ure%203572.jpg http://i5.photobucket.com/albums/y16...ure%203571.jpg So we needed a special tool in order to duplicate this feature... http://i5.photobucket.com/albums/y16...ure%203574.jpg http://i5.photobucket.com/albums/y16...ure%203575.jpg Spacing all marked out.... http://i5.photobucket.com/albums/y16...ure%203576.jpg Finished edge... http://i5.photobucket.com/albums/y16...ure%203577.jpg http://i5.photobucket.com/albums/y16...ure%203578.jpg http://i5.photobucket.com/albums/y16...ure%203579.jpg All ready for delivery! |
Re: 55 Wagon Progress
Kyle was off tonight so I missed getting some in-process pictures.. Still cleaning up welds to get the body ready for media blasting. The rear brackets for the gas tank straps were welded in...
http://i5.photobucket.com/albums/y16...ure%203582.jpg http://i5.photobucket.com/albums/y16...ure%203583.jpg I also worked on the passenger quarter this evening. One of the biggest problems with welding a horizontal seam down through the middle of the quarter on a car is the tendency for the seam to cave inwards.. I had some help this evening using the Watervliet hammer and a 24" radius die.. http://i5.photobucket.com/albums/y16...ure%203591.jpg Still have some highs and lows to address, but the weld seam is back out close to where it should be, and the Atlantic Ocean has calmed quite a bit.. http://i5.photobucket.com/albums/y16...ure%203590.jpg Next was to remove some creases in the cowl vent, seen here... http://i5.photobucket.com/albums/y16...ure%203584.jpg http://i5.photobucket.com/albums/y16...ure%203585.jpg Looks like someone may have kneeled on it at some point in the last 60 years. I've found the easy way to "highlight" an area like this in need of repair is to use a piece of 80 grit on the back side: http://i5.photobucket.com/albums/y16...ure%203587.jpg http://i5.photobucket.com/albums/y16...ure%203589.jpg Got the creases out using the body hammer with the chisel tip, and forgot to get the finished pictures. Next time... |
Re: 55 Wagon Progress
More great work! It all looks awesome from my chair.
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Re: 55 Wagon Progress
Thanks!
Here's the top side of the cowl vent..... http://i5.photobucket.com/albums/y16...ure%203607.jpg ....using this hammer.... http://i5.photobucket.com/albums/y16...ure%203609.jpg the marks on the back side show where the strikes were placed to remove the creases... http://i5.photobucket.com/albums/y16...ure%203610.jpg Kyle has the inner roof insulation about gone... http://i5.photobucket.com/albums/y16...ure%203611.jpg |
Re: 55 Wagon Progress
That came out real nice...Jim
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Re: 55 Wagon Progress
Awesome as usual..
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Re: 55 Wagon Progress
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Re: 55 Wagon Progress
Yes, the fender patches were done with tig, though it would be easier clean up.
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Re: 55 Wagon Progress
Our enclosed trailer has the white wagon wheels that always seem to turn rusty in a few years, so I have been trying different wheels to see what might work....
These are some late model Mustang wheels, the hub hole would need to be opened slightly, but the offset was, well off. http://i5.photobucket.com/albums/y16...ure%203619.jpg Perhaps on a fancy trailer with more stainless trim, but these just looked too much. Next, some plain Jane Ford Ranger wheels.... http://i5.photobucket.com/albums/y16...ure%203620.jpg Much better, correct offset, and no wheel modification needed. Just need to change up the color and add some stainless trim rings. I do have some bright orange, some bright red, and a few other colors in the paint locker.. :lol: Some before and after media blasting.. http://i5.photobucket.com/albums/y16...ure%203615.jpg http://i5.photobucket.com/albums/y16...ure%203616.jpg Two down, two to go. Can't get it all done in one night. And more weld grinding and other prep work on the wagon continues. Since the big cleanup in preparation for the class in the shop earlier this month, we haven't been able to find our quarter panel profile template, so Kyle made a couple of them, one for in front of the rear wheel, one behind, and we've been working on the weld seams and doing some metal bumping to minimize our stock in filler products. Drivers side is looking much better than it did last week, still about another day to go and the quarters should be good for epoxy primer.. http://i5.photobucket.com/albums/y16...ure%203617.jpg http://i5.photobucket.com/albums/y16...ure%203618.jpg |
Re: 55 Wagon Progress
Beautiful as always. Need to stock up on tips for the squarebody bedsides I'm gonna have to do.
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Re: 55 Wagon Progress
Thanks!
Well, we didn't get pictures of the funny part. Kyle and I loaded the frame in the trailer and headed off to the local car wash to remove the grease from the front cross member. We had quite a few stares and a couple horns honking as he pushed the frame around the car wash parking lot and I was sitting on the frame rail, maneuvering with the Jr. steering wheel. We found the tire presoak and a wire brush does wonders for the engine grease. The car wash attendant did not look too pleased, but never said a word. Back at the shop, bolting the adapter plates onto the frame... http://i5.photobucket.com/albums/y16...ure%203633.jpg http://i5.photobucket.com/albums/y16...ure%203639.jpg You can see in the above picture we used 1-1/2" long spacers to get a better access for media blasting the frame.. Disassembly starts.... http://i5.photobucket.com/albums/y16...ure%203649.jpg http://i5.photobucket.com/albums/y16...ure%203651.jpg http://i5.photobucket.com/albums/y16...ure%203652.jpg http://i5.photobucket.com/albums/y16...ure%203653.jpg After a few revolutions and a bit of air pressure, we had quite a pile of 60 year old dirt.. http://i5.photobucket.com/albums/y16...ure%203654.jpg Override springs from the era. The handyman wagons were often used as work vehicles, and this option helped with the heavy loads... http://i5.photobucket.com/albums/y16...ure%203655.jpg All stripped.... http://i5.photobucket.com/albums/y16...ure%203658.jpg http://i5.photobucket.com/albums/y16...ure%203661.jpg |
Re: 55 Wagon Progress
Had an early Chevy hood side show up at the shop tonight, the owner wanted a couple different versions of louver samples made up that he could hold against the hood on the car to better visualize. One style he was looking at lends from an early Alfa Romeo that extends the louvers onto the cowl, as shown in the green tape..
http://i5.photobucket.com/albums/y16...ure%203663.jpg We took a paper pattern of the details so the hood side could go back with him to use as a pattern for the opposite side that still needs to be made. http://i5.photobucket.com/albums/y16...ure%203664.jpg http://i5.photobucket.com/albums/y16...ure%203665.jpg Spot welded on some "end stops" for the louver die..... http://i5.photobucket.com/albums/y16...ure%203667.jpg .....and a squared plate for the back gauge. http://i5.photobucket.com/albums/y16...ure%203668.jpg http://i5.photobucket.com/albums/y16...ure%203669.jpg Louvers in the Lennox..... http://i5.photobucket.com/albums/y16...ure%203670.jpg http://i5.photobucket.com/albums/y16...ure%203671.jpg http://i5.photobucket.com/albums/y16...ure%203672.jpg http://i5.photobucket.com/albums/y16...ure%203674.jpg One sample down, one to go.. |
Re: 55 Wagon Progress
Very nice work...Jim
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Re: 55 Wagon Progress
Now that is some kool work. Rich
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Re: 55 Wagon Progress
You make it look so easy.
Fold your arms, nod your head, blink of an eye, poof, done. Perfect |
Re: 55 Wagon Progress
That... is awesome. Too cool.
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Re: 55 Wagon Progress
Thanks guys!
Well FedEx showed up today with a CL delivery, got a matched pair of 48" linear rails. The two bearing blocks will have a material clamp bolted to each block, and used on one rail. We'll get a chance to try it out on the second louver sample. Where we had been manually holding the workpiece against the back stop, this should work better with a simple glide back and forth once clamped in place.. http://i5.photobucket.com/albums/y16...ure%203676.jpg http://i5.photobucket.com/albums/y16...ure%203677.jpg http://i5.photobucket.com/albums/y16...ure%203678.jpg http://i5.photobucket.com/albums/y16...ure%203679.jpg While I was getting that squared away, Kyle was removing some scraps that were left on the frame from the original trans crossmember. http://i5.photobucket.com/albums/y16...ure%203683.jpg http://i5.photobucket.com/albums/y16...ure%203684.jpg He also removed the spot welded guides from the louver panel. The good part about samples is we can see what works well and what doesn't. Here we can see that we won't use spot welds next time as it's too much clean up. I think we'll give some stainless rivets a shot on version 2... http://i5.photobucket.com/albums/y16...ure%203680.jpg http://i5.photobucket.com/albums/y16...ure%203681.jpg http://i5.photobucket.com/albums/y16...ure%203682.jpg |
Re: 55 Wagon Progress
The more I looked at our panel with the spot weld carnage, the more I disliked the result, so with new linear guides installed, we made all new today using stainless pop rivets to hold the guides in place. This will leave a few 1/8" holes to fill, but should be much less issue than cleaning up after the spot welds...
We needed just a bit more throat for this set of "lengthened" hood sides, so one bolt was removed from the material clamp and then rotated the clamp inward 90". This lets the panel pass through rather than bottom out in the clamp. http://i5.photobucket.com/albums/y16...ure%203686.jpg Guides riveted in place.... http://i5.photobucket.com/albums/y16...ure%203687.jpg http://i5.photobucket.com/albums/y16...ure%203688.jpg http://i5.photobucket.com/albums/y16...ure%203689.jpg Here's the new version 1, much cleaner, less distortion, and we can re-use the guides... http://i5.photobucket.com/albums/y16...ure%203694.jpg http://i5.photobucket.com/albums/y16...ure%203695.jpg http://i5.photobucket.com/albums/y16...ure%203696.jpg The cowl piece was done without guides.... http://i5.photobucket.com/albums/y16...ure%203700.jpg And version 2 with the cowl piece..... http://i5.photobucket.com/albums/y16...ure%203699.jpg Dave (the car owner) stopped by this afternoon and picked up the samples, and indicated he was being over-ruled by most parties on louvers in the cowl, so likely that version won't be used... |
Re: 55 Wagon Progress
....And, in the interest of showing the good with the bad, the lessons learned if you will, Safety tip of the day is to deburr your sheet metal even if it's only for practice pieces....
http://i5.photobucket.com/albums/y16...ure%203685.jpg |
Re: 55 Wagon Progress
OUCH!!!!!!...Jim
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Re: 55 Wagon Progress
That's a good chunk, keep it clean my brother inlaw just spent a week in the hospital for a infection in hes finger.
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Re: 55 Wagon Progress
So far so good, nothing oozing.. :metal:
Tonight we worked on the frame, used some poster board to make a pattern for a strengthening plate to span the pocket kit on each frame rail.. http://i5.photobucket.com/albums/y16...ure%203705.jpg While Kyle filled in some frame holes by plug welding to the pocket kit, I cut out the frame plates... http://i5.photobucket.com/albums/y16...ure%203706.jpg http://i5.photobucket.com/albums/y16...ure%203708.jpg http://i5.photobucket.com/albums/y16...ure%203709.jpg http://i5.photobucket.com/albums/y16...ure%203710.jpg And the shop vacuum is about on it's last leg, it leaves behind about as much as it picks up. For anyone at DYSON or SHARK vacuum that would like to send a test sample, we can sure do a stress analysis on your product.. :lol: |
Re: 55 Wagon Progress
More prep and welding on the frame....
http://i5.photobucket.com/albums/y16...ure%203722.jpg http://i5.photobucket.com/albums/y16...ure%203723.jpg http://i5.photobucket.com/albums/y16...ure%203724.jpg http://i5.photobucket.com/albums/y16...ure%203725.jpg and we cleared out the remaining vacuum inventory from the yard sale pile.. This one is working a bit better! http://i5.photobucket.com/albums/y16...ure%203721.jpg We've been going through a dry spell here in the shop, it's been quite some time since we've seen any yellow body panels. Soon to change.... http://i5.photobucket.com/albums/y16...ure%203726.jpg http://i5.photobucket.com/albums/y16...ure%203727.jpg |
Re: 55 Wagon Progress
My first summer working in a body shop was spent sandblasting school buses from the cowl back. I think we did 5 that summer. That was 1974
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Re: 55 Wagon Progress
Were they trying to keep ahead of the salt corrosion in stripping/repainting?
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Re: 55 Wagon Progress
We were stripping and repainting due to old paint peeling in spots. We did one every two weeks. It took as long to tape the windows with cardboard as it did to actually blast them. The paint blew right off. Then sanding ,priming painting plus the two tone. All in Dupont Dulux enamel
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Re: 55 Wagon Progress
Lovin' the louvers. What is the pocket kit for? Will this one be going bags and a 4-link?
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