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Re: 55 Wagon Progress
First let me say thanks for the invite to hang out in your shop for the day and it's probably a good thing I don't live closer as I would never leave.
The craftsman ship on the 55 is just as described in this thread but seeing it in person puts it on a whole nother level. |
Re: 55 Wagon Progress
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Re: 55 Wagon Progress
You guys are too much! James, stop by anytime..
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Re: 55 Wagon Progress
Tonight we have both seat belt retractor anchor plates welded and waiting for apprentice E to media blast and epoxy prime..
http://i5.photobucket.com/albums/y16...6/IMG_3310.jpg http://i5.photobucket.com/albums/y16...6/IMG_3311.jpg Next, we have the side filler panels to either side of the fold down rear seat that don't fit with those pesky wheel tubs in the way... http://i5.photobucket.com/albums/y16...6/IMG_3312.jpg http://i5.photobucket.com/albums/y16...6/IMG_3313.jpg So we plan to make new ones, with a relief to fit snugly to the wheel tubs at the bottom end.. We used the Baileigh MH19 hammer and the shrinking dies to shape a piece of 14 gauge cold rolled to fit the wheel tub. Glad I didn't have to do all that shrinking by hand. http://i5.photobucket.com/albums/y16...6/IMG_3316.jpg http://i5.photobucket.com/albums/y16...6/IMG_3317.jpg http://i5.photobucket.com/albums/y16...6/IMG_3318.jpg http://i5.photobucket.com/albums/y16...6/IMG_3323.jpg A flat piece from the top section will be welded to this piece, and then foam will be glued to the assembly and upholstered to match the seat.. |
Re: 55 Wagon Progress
To catch up on the wagon, the seat belt retractor anchor bracket will be located inside the quarter panel, here we are laying out for the plug weld holes that hold it in place...
http://i5.photobucket.com/albums/y16...6/IMG_3349.jpg Holes piloted, then use the burnishing brush to remove the paint from the weld area... http://i5.photobucket.com/albums/y16...6/IMG_3350.jpg http://i5.photobucket.com/albums/y16...6/IMG_3352.jpg Then the holes are enlarged for plug weld size, I use a letter A and plenty of heat. http://i5.photobucket.com/albums/y16...6/IMG_3355.jpg Back to our rear seat back modification, some 14 gauge steel is shrunk in the Baileigh MH19 to fit the driver's wheel well.. http://i5.photobucket.com/albums/y16...6/IMG_3361.jpg After some cleanup on the Tommasini cast wheeling machine... http://i5.photobucket.com/albums/y16...6/IMG_3362.jpg http://i5.photobucket.com/albums/y16...6/IMG_3363.jpg Meanwhile, Mike has media blasted the anchor brackets and is here spraying them with SPI epoxy primer... http://i5.photobucket.com/albums/y16...6/IMG_3365.jpg http://i5.photobucket.com/albums/y16...6/IMG_3370.jpg http://i5.photobucket.com/albums/y16...6/IMG_3379.jpg The 14 gauge is then held to the wheel wells and marked a line parallel to the seat frame. We'll use this line to start the transition to flat, using a linear stretch die in the MH19. http://i5.photobucket.com/albums/y16...6/IMG_3371.jpg http://i5.photobucket.com/albums/y16...6/IMG_3374.jpg http://i5.photobucket.com/albums/y16...6/IMG_3377.jpg Linear stretch die also used to add this detail to blend into the bottom part... http://i5.photobucket.com/albums/y16...6/IMG_3384.jpg http://i5.photobucket.com/albums/y16...6/IMG_3386.jpg Tacked together and fitted.... http://i5.photobucket.com/albums/y16...6/IMG_3387.jpg Tig welded.... http://i5.photobucket.com/albums/y16...6/IMG_3389.jpg This should JUST hide the wheel well, but doesn't look like the foam will be all that thick at the bottom... http://i5.photobucket.com/albums/y16...6/IMG_3391.jpg Weld dressed and another fit, I was going to trim the sides but we'll be adding some stiffener beads to the flat area, so we'll wait until after that process to trim the sides. http://i5.photobucket.com/albums/y16...6/IMG_3395.jpg http://i5.photobucket.com/albums/y16...6/IMG_3397.jpg http://i5.photobucket.com/albums/y16...6/IMG_3396.jpg |
Re: 55 Wagon Progress
Excellent detail as always...Jim
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Re: 55 Wagon Progress
Thanks Jim!
Saturday Mike worked on the 55, with the seat belt retractor anchor plates now epoxied and cured for a week, they're ready to weld inside the quarters. He clamped them in place, scribed all the holes, removed them and cleaned paint off the hole locations.... http://i5.photobucket.com/albums/y16...6/IMG_3499.jpg clamped in, ready to plug weld..... http://i5.photobucket.com/albums/y16...6/IMG_3498.jpg http://i5.photobucket.com/albums/y16...6/IMG_3505.jpg http://i5.photobucket.com/albums/y16...6/IMG_3509.jpg then he dressed the plug welds on the anchor plates as well as a few remaining ones on the drivers bucket seat pan. next on the list is to fabricate some arm rests for the rear seat area that will also serve to enclose the seat belt retractors. |
Re: 55 Wagon Progress
With the Biederman fenders out of the building, its time to work on the 55's rear seat bolsters. Time to assemble the parts for the passenger side..
http://i5.photobucket.com/albums/y16...6/IMG_3594.jpg http://i5.photobucket.com/albums/y16...6/IMG_3599.jpg TIG welded together... http://i5.photobucket.com/albums/y16...6/IMG_3601.jpg ....and cleaned up.... http://i5.photobucket.com/albums/y16...6/IMG_3602.jpg Back to the drivers side, all the edges will be tipped forward to eliminate the possibility of sharp edges cutting through the upholstery.. http://i5.photobucket.com/albums/y16...6/IMG_3604.jpg http://i5.photobucket.com/albums/y16...6/IMG_3605.jpg This is the edge adjacent to the center fold down seat, so we wanted it nice and straight.. http://i5.photobucket.com/albums/y16...6/IMG_3606.jpg To better check that we were straight across the uneven surfaces, we used the laser again... https://www.youtube.com/watch?v=s3TwP6NaCKU Seats mocked up again..... http://i5.photobucket.com/albums/y16...6/IMG_3610.jpg .....and laser used to get a straight edge on the outside.. http://i5.photobucket.com/albums/y16...6/IMG_3614.jpg for more edge tipping.... http://i5.photobucket.com/albums/y16...6/IMG_3617.jpg http://i5.photobucket.com/albums/y16...6/IMG_3618.jpg http://i5.photobucket.com/albums/y16...6/IMG_3619.jpg Hopefully we can finish this up in the morning and start cutting out the foam pad.. |
Re: 55 Wagon Progress
Robert, very nice detail on the edges...Jim
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Re: 55 Wagon Progress
Thanks Jim!
Here's the panel with all the edges tipped forward, clamped in place.. http://i5.photobucket.com/albums/y16...6/IMG_3621.jpg Some poster board templates were traced from the steel part, then trimmed out and transferred to the foam. http://i5.photobucket.com/albums/y16...6/IMG_3622.jpg Used the electric bread knife from the kitchen (if anyone asks you haven't seen it...) to trim out the foam, makes short work of it... http://i5.photobucket.com/albums/y16...6/IMG_3623.jpg roughed out... http://i5.photobucket.com/albums/y16...6/IMG_3625.jpg Test fit for marking the profile... http://i5.photobucket.com/albums/y16...6/IMG_3627.jpg trimmed /sculpted to size with the bread knife and 3" roloc. Use a worn disc on the sander, the fresh ones tend to grab.. http://i5.photobucket.com/albums/y16...6/IMG_3628.jpg http://i5.photobucket.com/albums/y16...6/IMG_3629.jpg This fills out the seat pretty nicely and hides that wheel tub that protrudes into the back side of the seat. http://i5.photobucket.com/albums/y16...6/IMG_3632.jpg http://i5.photobucket.com/albums/y16...6/IMG_3633.jpg |
Re: 55 Wagon Progress
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Been a while for any updates, been driving around seeing the countryside. Happened across this nice v-dub today...
Attachment 1668257 John, it was great finally getting to meet, you have some nice projects going on in your shop. Holler if you ever venture north! |
Re: 55 Wagon Progress
It was great to finally meet you too! Appreciate you taking the time to stop by and hang out for awhile.
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Re: 55 Wagon Progress
After travelling the countryside, it was back to the grind, took delivery of the bus with the cracked hood this past Wednesday.
http://i5.photobucket.com/albums/y16...0/IMG_3218.jpg After removing headlights, I ground out the cracked areas, which relieved the tension and allowed the panels to lay flat again. Epoxy was used between the outer and inner layers, clamped, and let things set up. http://i5.photobucket.com/albums/y16...0/IMG_3811.jpg After a couple layers added.... http://i5.photobucket.com/albums/y16...0/IMG_3815.jpg Left this to cure in the sun for a couple days, then back at it on Saturday. Ground smooth and hopefully the last layer added... http://i5.photobucket.com/albums/y16...0/IMG_3833.jpg http://i5.photobucket.com/albums/y16...0/IMG_3840.jpg Back on the wagon, we needed to close off the back side of the rear seat.. We have some square tubing to use but needed a radius bender. The upper part of the buffer stand looks like it may work. As I've told Mike, everything is a tool.. http://i5.photobucket.com/albums/y16...6/IMG_3822.jpg Add a welder and a piece of round stock for an anchor... http://i5.photobucket.com/albums/y16...6/IMG_3824.jpg First test... http://i5.photobucket.com/albums/y16...6/IMG_3825.jpg Four pieces needed... http://i5.photobucket.com/albums/y16...6/IMG_3827.jpg All TIG welded together... http://i5.photobucket.com/albums/y16...6/IMG_3839.jpg |
Re: 55 Wagon Progress
Nice closure for the back seat, will have a few feet for storage...Jim
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Re: 55 Wagon Progress
Thanks Jim. The sides will have a wrap-around..
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Re: 55 Wagon Progress
Extra storage compartment or speaker area? hmmm
Diggin' the innovative bender. |
Re: 55 Wagon Progress
bass speaker, amp, ???
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Re: 55 Wagon Progress
Made a set of C-pillars for a 56 wagon, they weld into the window opening and separate the fixed rear wrap around window from the roll down window for the back seat..
http://i5.photobucket.com/albums/y16...g/IMG_3871.jpg This is where they locate... http://i5.photobucket.com/albums/y16...g/IMG_3864.jpg http://i5.photobucket.com/albums/y16...g/IMG_3865.jpg http://i5.photobucket.com/albums/y16...g/IMG_3866.jpg Meanwhile apprentice E is prepping some bus parts for paint, here working on a back bumper... http://i5.photobucket.com/albums/y16...0/IMG_3868.jpg |
Re: 55 Wagon Progress
Yesterdays progress.... Apprentice E got the bus bumper end caps removed by drilling out the rivets, and then media blasted the caps so they will be ready for paint...
http://i5.photobucket.com/albums/y16...0/IMG_3898.jpg We needed some tooling for the next phase of the 55 wagon's interior fabrications, the radius we installed on the rear seat back framework will need to be duplicated onto the sheet metal covering. A trip to Hill Top welding had produced a suitable piece of 4" pipe. The Pexto shear has a t-slot along the front for it's support arms and we'll use this to bolt on a couple angle brackets to support this pipe along the front. A slight gap behind the pipe will allow us to use it as a fulcrum in adding a radius to our panel... Mike worked on adding some end caps to our radius die.... http://i5.photobucket.com/albums/y16...g/IMG_3899.jpg http://i5.photobucket.com/albums/y16...g/IMG_3900.jpg http://i5.photobucket.com/albums/y16...g/IMG_3901.jpg http://i5.photobucket.com/albums/y16...g/IMG_3902.jpg http://i5.photobucket.com/albums/y16...g/IMG_3904.jpg Need a ground clamp for a standing piece of pipe? set it on a flanged piece of sheet metal, instant clamp location.... http://i5.photobucket.com/albums/y16...g/IMG_3905.jpg More to come on that.... Meanwhile, our sheet metal panel will also serve to cover the rear bass speaker. Not wanting a grille showing, we plan on using upholstery cloth to conceal the speaker. Rather than a big gaping hole that would more readily show the location regardless, some slots will better support the upholstery cloth. So lets make some nibbling tooling.. This punch will be approx. 3/8 diameter and is made of 4140 oil hardening stock so we can heat treat when complete for better tool life.. http://i5.photobucket.com/albums/y16...g/IMG_3897.jpg End is formed slightly concave to give a better cutting edge.. http://i5.photobucket.com/albums/y16...g/IMG_3903.jpg Bottom die gets a clearance hole for the 3/8 punch, then it gets bored from the bottom end using 1/2" bit to within about 1/8" of the top surface. This will allow better gravity flow of any chips passing through our bottom die.. http://i5.photobucket.com/albums/y16...g/IMG_3908.jpg http://i5.photobucket.com/albums/y16...g/IMG_3910.jpg Then we'll need an exit chute, so a 1/2" angled hole is drilled through the side and a 1/2" plug made to fill the remainder... http://i5.photobucket.com/albums/y16...g/IMG_3912.jpg The plug bottom gets chamfered and welded into the bottom die, then a ball end die grinder is used to fine tune the exit chute... http://i5.photobucket.com/albums/y16...g/IMG_3913.jpg A "shoe" is formed to hold down the workpiece, as otherwise the punch tends to lock onto the panel after the first punch and raise it in the air, thus preventing any material feed... http://i5.photobucket.com/albums/y16...g/IMG_3925.jpg An action video.... https://www.youtube.com/watch?v=Zzh1...ature=youtu.be Our test slot.... this may work yet! http://i5.photobucket.com/albums/y16...g/IMG_3924.jpg |
Re: 55 Wagon Progress
Today I got the pipe and brackets that Mike made up added to the front of the Pexto Shear. The top of the pipe is set up the same height as the surface of the shear, so no interference in using the shear. The pipe is 49" long so it can be used for a full sheet if we have enough oomph to bend it. Here the finished product:
https://www.youtube.com/watch?v=Fm1blt_jX7k Sometimes you get lucky, here's the radius from our 4" pipe as matched to our seat back... http://i5.photobucket.com/albums/y16...g/IMG_3938.jpg Also made up some patch panels for my brother in law's El Camino. He brought some parts over that he had cut out, so we fabbed up some new parts, here's a sample... http://i5.photobucket.com/albums/y16...g/IMG_3936.jpg |
Re: 55 Wagon Progress
Robert, nice to see someone make their own tools, and know how to use them. Always happy to see your post, I learn something each time...Jim
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Re: 55 Wagon Progress
Dang man! You have some mad skill! You sir are my hero!
That 55 wagon is un real.:metal: |
Re: 55 Wagon Progress
Robert, excellent work as always, looks great...Jim
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Re: 55 Wagon Progress
I don't always comment, but I tune in with the hopes that some of this skill will be absorbed. Always top notch impressive work, Thanks for sharing ...Ed
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Re: 55 Wagon Progress
Thanks for the comments guys!
More work on the seat back, a test bend to see how well it matches our corner.... http://i5.photobucket.com/albums/y16...6/IMG_4004.jpg http://i5.photobucket.com/albums/y16...6/IMG_4005.jpg Then to bend the radius on a piece of 19 gauge for the full width... http://i5.photobucket.com/albums/y16...6/IMG_4006.jpg http://i5.photobucket.com/albums/y16...6/IMG_4007.jpg Then to bend down a flange to "hook" the frame.... http://i5.photobucket.com/albums/y16...6/IMG_4008.jpg The metal is thinned at the bend line using a tipping die to give us a more crisp bend... http://i5.photobucket.com/albums/y16...6/IMG_4009.jpg Bent at 90* in the magnetic brake.. http://i5.photobucket.com/albums/y16...6/IMG_4010.jpg http://i5.photobucket.com/albums/y16...6/IMG_4011.jpg http://i5.photobucket.com/albums/y16...6/IMG_4013.jpg Next we slotted the panel for our 10" bass speaker. This should let out the sound but still support our upholstery material for a more subtle look.. http://i5.photobucket.com/albums/y16...6/IMG_4019.jpg http://i5.photobucket.com/albums/y16...6/IMG_4022.jpg Then the bottom flange is also thinned at the bend and bent on the magnetic brake.. https://youtu.be/krzfbvw9DV8 http://i5.photobucket.com/albums/y16...6/IMG_4023.jpg http://i5.photobucket.com/albums/y16...6/IMG_4025.jpg .....and our test fit into the car... http://i5.photobucket.com/albums/y16...6/IMG_4026.jpg |
Re: 55 Wagon Progress
Very nice...Jim
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Re: 55 Wagon Progress
Hey Robert, very nice fabrication Thanks for taking the time and posting as I enjoy learning techniques from you, Nate
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Re: 55 Wagon Progress
Thanks for the comments guys. Nate, didn't get a chance to respond to your comments the other day and now I see they've changed, so let me go on memory here.
I appreciate you guys giving feedback, even if you don't care for something. Sometimes a person gets tunnel vision, so outside suggestions come in handy. I'm not sure I even like it, but this needs to be a utilitarian of sorts back seat. The owner has it in her mind she needs a bumping stereo, and also needed a location for amp and speaker. The wagon doesn't give much option for hiding such things without risking tire spray, so behind the seat it was. The original rear seat folded in such a way to give a flat loading area all the way to the back side of the front seats. She would rather use the comfort of the newer seat that came with the buckets over the original, and this was also easier to fit to the mini-tub, so much for hauling plywood :lol: The newer seat does fold toward the front, so this would allow for access to anything inside the void. We are also trying to leave room for the cleaning supplies, out of sight, out of mind. We didn't want to extend the sides into the window area and affect the interior garnish moldings that surround the windows, hence the transition corner pieces that blend into the wheel wells.. In the end, I think the upholstery design is going to make or break it. Myself, I tried to talk her out of a stereo. A stroker motor with 40 series flowmasters, there will be plenty to listen to. If you don't like the station, roll down the window! :lol: |
Re: 55 Wagon Progress
Today was paint day for the remaining bus parts. One hood, three rear skirts, and attaching hardware.. After a sealer coat of SPI Epoxy..
http://i5.photobucket.com/albums/y16...0/IMG_4031.jpg http://i5.photobucket.com/albums/y16...0/IMG_4033.jpg And our yellow... http://i5.photobucket.com/albums/y16...0/IMG_4034.jpg http://i5.photobucket.com/albums/y16...0/IMG_4036.jpg http://i5.photobucket.com/albums/y16...0/IMG_4038.jpg We'll let these cure a bit and get 580 put back together this weekend.. |
Re: 55 Wagon Progress
Today the hood was reinstalled, all the bits bolted back together, and the rear skirt replaced..
http://i5.photobucket.com/albums/y16...0/IMG_4042.jpg http://i5.photobucket.com/albums/y16...0/IMG_4044.jpg http://i5.photobucket.com/albums/y16...0/IMG_4045.jpg http://i5.photobucket.com/albums/y16...0/IMG_4047.jpg http://i5.photobucket.com/albums/y16...0/IMG_4048.jpg All together and ready for pick up tomorrow.. http://i5.photobucket.com/albums/y16...0/IMG_4049.jpg So we can get back to the 55 tomorrow... |
Re: 55 Wagon Progress
Well last night found us carpenterin.... using some 3/4 MDF and some construction adhesive...
http://i5.photobucket.com/albums/y16...6/IMG_4058.jpg http://i5.photobucket.com/albums/y16...6/IMG_4059.jpg http://i5.photobucket.com/albums/y16...6/IMG_4060.jpg http://i5.photobucket.com/albums/y16...6/IMG_4061.jpg http://i5.photobucket.com/albums/y16...6/IMG_4063.jpg http://i5.photobucket.com/albums/y16...6/IMG_4064.jpg The amp will get mounted on the access cover. |
Re: 55 Wagon Progress
Got the drivers corner for the rear seat back tig welded in place and flange folded. Now for the passenger side.
https://www.youtube.com/watch?v=Z-61G1Q1EWo On a side note, officially gave Photobucket the boot as my subscription expired last Friday. Robert isn't paying their extortion fees. Surprised the pictures are still showing... |
Re: 55 Wagon Progress
Robert, this photobucket crap stinks, would hate to lose all your great work shown here...Jim
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Re: 55 Wagon Progress
PB has made itself into the most hated site of this decade. wish there was a hack to correct it. i started using imgur. real easy to upload.
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Re: 55 Wagon Progress
Still haven't set up the new photo hosting, so todays update via youtube. Got the passenger corner all formed up and Tig welded in place for the rear seat back enclosure..
https://www.youtube.com/watch?v=VsZ1zktynes |
Re: 55 Wagon Progress
Well I think I have google images figured out now, so lets try an update on the wagon.
With the back seat rear enclosure and it's frame both sprayed in epoxy, time to assemble the two together. I didn't want to use hardware/rivets on the skin as I thought it would stay flatter under the upholstery without. Also, with the amp and bass speaker inside the enclosure, we needed something to limit vibration of the adjacent pieces. Our choice is to use some body molding adhesive tape to join the two together. https://lh3.googleusercontent.com/bD...Y=w684-h911-no The tape is applied to the frame, and then the skin attached on top of that.. https://lh3.googleusercontent.com/E8...c=w684-h911-no https://lh3.googleusercontent.com/rS...A=w684-h911-no Next, we need to work on our console and the shifter inside of it. We have the console that came with the 2002 Monte Carlo interior, but it has far too much plastic that it didn't belong. In looking at other options, we decided on the horse shoe shifter used on the Chevelle. In conducting a test fit of the cable, we found it's trajectory path was much too straight where it either lifted the front of the shifter, or pulled the bulkhead fitting out of the "tunnel" mockup. https://lh3.googleusercontent.com/Bp...=w1215-h912-no Shifter lift: https://www.youtube.com/watch?v=b9-HXW7oNYg Our solution was to raise the cable exit from the shifter housing higher in order to have a better arc of the cable for entry through the floor. Here a "relocation bracket" has been added: https://lh3.googleusercontent.com/o4...=w1215-h912-no Bracket all welded in place, looks like this will work for our shifter, return policy officially void now, but cable path fits much better through the floor: https://www.youtube.com/watch?v=LySdi8tifvQ We also needed to finalize seat belts for the rear seats. These are 12 gauge CRS pieces that are plug welded to the floor pan, 1/2" diameter bolt holding the anchor points for inner seat belts. https://lh3.googleusercontent.com/6T...M=w684-h911-no The outer belts needed to be all the way out to the wheel well, and to better "anchor" we made similar 12 ga brackets, this one with a hemmed end to "hook" the pinch weld seam of the floor pan/wheel well, then plug welded in place to the wheel well. Again, a 1/2" bolt will anchor the seat belt: https://lh3.googleusercontent.com/Yl...A=w729-h912-no While Mike and Jake started the layout of the console......... https://lh3.googleusercontent.com/ev...I=w684-h911-no ......I fabbed up some bucket seat brackets out of 16 ga CRS for a 37 Ford. These had to be 3" high and only 1-1/2" wide, which was too high for my gooseneck die in the press brake. Chose to make them in two pieces and fusion tacked together using the TIG. https://lh3.googleusercontent.com/4M...M=w684-h911-no |
Re: 55 Wagon Progress
Great to see you back. Looking forward to seeing the progress and excellent fabbing.
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Re: 55 Wagon Progress
Robert, I agree glad to see you back, always enjoy your post...Jim
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Re: 55 Wagon Progress
Thanks guys!
Console fabrication https://lh3.googleusercontent.com/PU...w=w995-h746-no Bottom and under dash edges are hemmed, folded flanges will support the filler panel between each side.. https://www.youtube.com/watch?v=pV1yiaFoUfQ Fitting up the corner radius https://www.youtube.com/watch?v=1NdR3c_S8nE |
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