Re: 55 Wagon Progress
 

Nice repair piece...Jim

Re: 55 Wagon Progress
 

Thanks Jim!


After a week in FL for the day job, time to get the inner patch welded in place.


Tacked using the TIG:


https://i5.photobucket.com/albums/y1...7/IMG_5725.jpg


video:


https://youtu.be/UixLOAZejMI


https://i5.photobucket.com/albums/y1...7/IMG_5731.jpg


welds dressed:


https://i5.photobucket.com/albums/y1...7/IMG_5734.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5736.jpg


Epoxy primer added:


https://i5.photobucket.com/albums/y1...7/IMG_5738.jpg

Re: 55 Wagon Progress
 

wow ..great work on something thatll never be seen..shows commitment...

Re: 55 Wagon Progress
 

nice!

Re: 55 Wagon Progress
 

Thanks Guys!


Now to get our outer patch fabricated.. The corner is going to need a GRUNCH of shrinking.. We started on the Baileigh, but the dies are only going to get us so far. So some tuck shrinking with some heat for persuasion was used..


https://i5.photobucket.com/albums/y1...7/IMG_5745.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5747.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5750.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5751.jpg


A tipping wheel in the bead roller was used to mark our bend line, and an upper press brake die used as an anvil to hammer the flanges over..


https://i5.photobucket.com/albums/y1...7/IMG_5753.jpg


Some hammer action to stretch the corner flange so it will tip the full 90*


https://www.youtube.com/watch?v=_FEIEQoGzdg


https://i5.photobucket.com/albums/y1...7/IMG_5755.jpg


I missed some in process pictures here, but various hammers, anvils, punches, and other implements of destruction were employed to give us our basic shape...


https://i5.photobucket.com/albums/y1...7/IMG_5757.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5759.jpg


After a bit of fine tuning, it is trimmed and fitted into the A Pillar...


https://www.youtube.com/watch?v=HCDRj5uOU3s


and the windshield stainless is test fit for good measure..


https://i5.photobucket.com/albums/y1...7/IMG_5763.jpg


The finished piece is media blasted (Barton Garnet) so the SPI epoxy primer will have a good bite. The inside is primed as a bit more preventative measure over factory....


https://i5.photobucket.com/albums/y1...7/IMG_5765.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5768.jpg


The flange is quite small compared to what we normally plug weld, so we opted for a .169 drill bit to keep the heat away from the edge...


https://i5.photobucket.com/albums/y1...7/IMG_5769.jpg


In order to clean he primer out the inside of our plug weld holes, we flattened and backfaced our drill bit to mimic an end mill....


https://i5.photobucket.com/albums/y1...7/IMG_5770.jpg


Does a good job of giving us nice clean metal for a good weld..


https://i5.photobucket.com/albums/y1...7/IMG_5771.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5772.jpg


much better....


https://www.youtube.com/watch?v=T8ajeDMzOJ0





.

Re: 55 Wagon Progress
 

Just great work...Jim

Re: 55 Wagon Progress
 

Unreal.....

Re: 55 Wagon Progress
 

Robert, Let me start with: WOW, just WOW! As an autobody craftsman for over 30 years, I can sure appreciate the level of workmanship!

I'd like to mention something that came to me while looking at the photos of the sign you guys are working on. A little late to the party, but it may still be of value at some point.
I realize that metal glue is not something a person at your level of skills would commonly use, however in the case of that sign...it would be THE way to go! I prefer the Fusor 208 for things like that. Everywhere the gaps are where sheetmetal is attached to the beaded area & where you put the plug
welds on the overlapping areas...that would be MUCH easier with glue & because it is a solid attachment it is far superior, doesn't create heat damage & nothing to grind, ect. The uniform nature of the seam makes it where with a bit of care with a finger or a bodyfiller spreader ground to a rounded corner...a near perfect "rolled edge" transition can be made rather easy while sealing it all up.

I can only say: "Please discus what Im suggesting with your paint/material jobber & give it a try!" Its not a "cure-all", but it has its place & that sign is a PERFECT example! Take Care, Lorne

Re: 55 Wagon Progress
 

Thanks for the comments guys! Lorne, appreciate the insight, but like you said, I'm a bit far along on the sign at this point. The two "permanent" sides are welded, the opposite sides will be a screw and rivnut assembly to allow removal of one side for access to the electrics.. Have to keep that option open for the next project like that..

Thanks!!

Re: 55 Wagon Progress
 

Here's some of the forming process of our A-Pillar fabrication that I missed the other day. Did a couple time lapse videos, first shows the shrinking of the corner. The Vise Grip tucking tool, torch, and hammer is used to get the corner to come down about a 20* angle, then the two flanges were folded, which gives us one big tuck. At that point wide VEE is heated up and the high spots of the flange corner is hammered back into itself. Repeat for the next high spot, until the corner is folded where you want it.


https://www.youtube.com/watch?v=jH6lybdj94A


Here's the corner shrink complete...

https://i5.photobucket.com/albums/y1...2/IMG_5791.jpg

Then the barrel end hammer is used to make the joggle creases by using an upper die from our press brake as a post dolly. That’s the basic process.


https://www.youtube.com/watch?v=-ZBpjeUw6us



If you find the time lapse too fast, you can change playback speed on YouTube to slow things down a bit..
.



.

Re: 55 Wagon Progress
 

Robert,,,yall gonna have to quit mixing redbull and 5hr energys..haha...thats a neat process though

Re: 55 Wagon Progress
 

I may need a few more.... :haha:


Today we worked on some rust prevention up inside the roof. This is between the roof skin and the perimeter structure just above the windows.


https://i5.photobucket.com/albums/y1...7/IMG_5819.jpg


The car was rolled on it's side and SPI epoxy poured into the area, acid brush was used to cover everything we could..


https://i5.photobucket.com/albums/y1...7/IMG_5820.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5821.jpg


Once the entire passenger side had been flooded around to the liftgate hinge, we rolled the car right side up again. It wasn't long that we had paint dripping on the top of the rocker panel.. It was running down inside the A Pillar and running out the bottom of the dogleg. This is a good indicator of exactly where the roof condensation runs to when it reaches the A Pillar, and why we had rust issues there.


https://i5.photobucket.com/albums/y1...7/IMG_5825.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5826.jpg


Here's a picture of when we opened the roof for rust repair, showing what the condensation did for us..


https://i5.photobucket.com/albums/y1...7/IMG_5831.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5832.jpg


So our primer is sealing the joint between the roof skin and the structure.. We found an opening above the windshield that would help us to flood the front seam....


https://i5.photobucket.com/albums/y1...7/IMG_5830.jpg


We opened up an acid brush to form a funnel, and poured SPI Epoxy in the area..


https://i5.photobucket.com/albums/y1...7/IMG_5833.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5834.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5835.jpg


A puddle out of the A Pillar dogleg shows we have good flow through the windshield...


https://i5.photobucket.com/albums/y1...7/IMG_5837.jpg


To insure everything was covered above the windshield header, we joined two acid brushes for an extended reach over the header, and bent to match the roof skin profile....


https://i5.photobucket.com/albums/y1...7/IMG_5838.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5839.jpg

Re: 55 Wagon Progress
 

Robert, that should take care of any problems, later down the road. Nice work as always...Jim

Re: 55 Wagon Progress
 

Unbelievable work!

I do have a question - if you want to get back in tight or mostly enclosed spaces where rust grows but either don’t have the skills or it just doesn’t make sense for a particular project, what do you think of using a product like Eastwood’s internal coating and rust encapsulation?

https://www.eastwood.com/eastwood-in...z-aerosol.html

For ex., I have an old Jeep pickup and i know there has to some level of rust in the rockers, pillars, inside roof edges, etc. with this product and their flex hose I can get in many spaces and spray them reasonably well and that has to be certainly better than nothing? Are there other better products or ways to deal with these areas?

Thanks for allowing us to follow along! I have been encouraged to try some metal work I wouldn’t have if I didn’t see what you do.

Re: 55 Wagon Progress
 

cavity wax maybe?

Re: 55 Wagon Progress
 

Scott, I’ve never used the Eastwood product to speak to how well it works. I would say if you think there are rust issues I would check into whether replacement rockers or other panels are needed. I try to encapsulate the rust in a trash can as I install new metal. ;)

Re: 55 Wagon Progress
 

Robert - love that trash can part. Yeah I realize that not replacing the parts and trying to stop further rust by spraying magic paint on them is kinda mickey mouse. However, it was a $2500 Jeep when I bought it and after I put a lot of $$ into it it will likely still be a $2500 Jeep. They don't make many spare parts at all (I was lucky to find floors) and I need to stop it from rusting away so I'm looking for alternatives.

I already bought several parts trucks or major sections and cut all the good metal out of them I could find. I will be trimming parts and replacing rusty sections where I can, as long as the rust doesn't spread further before I get there!

Anyway, I'll just continue to watch you do your artistry and magic and try to dance that line between weenie work and something better! :)

Re: 55 Wagon Progress
 

Scott, we all started somewhere. Recognizing room for improvement will normally prompt one to improve skills as you learn.


Progress this weekend, We had originally left the factory jute insulation under the roof supports, thinking we could just butt up to it with the new stuff. After installing the Noico inside the doors, I guess my OCD wasn't about to leave the old stuff in the roof. So the bottom edge of the roof supports were scribed on the driver's side for relocation purposes, de-spot welded, and pulled downward enough to scrape off the old jute..


https://i5.photobucket.com/albums/y1...7/IMG_5888.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5889.jpg


https://www.youtube.com/watch?v=ZOj1...ature=youtu.be


https://i5.photobucket.com/albums/y1...7/IMG_5892.jpg


The bare area is then scuffed with 80 grit and two coats of SPI epoxy primer applied.. After that sets up we applied the Noico sound deadening mat to the inside of the roof skin. Then the roof supports are aligned with our scribed marks and plug welded in place..


https://i5.photobucket.com/albums/y1...7/IMG_5901.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5899.jpg


https://i5.photobucket.com/albums/y1...7/IMG_5900.jpg



Mike has been plugging along on the Drummers Lounge sign, the arrow is close to done, it still needs fastening hardware added for the access panels, and holes added for the lights..


https://i5.photobucket.com/albums/y1...2/IMG_5908.jpg


https://i5.photobucket.com/albums/y1...2/IMG_5907.jpg


https://i5.photobucket.com/albums/y1...2/IMG_5904.jpg

Re: 55 Wagon Progress
 

Robert, hope you don't get tired of me saying the same thing over and over "Great work as always"...Jim

Re: 55 Wagon Progress
 

Drummers sign getting neon?

Re: 55 Wagon Progress
 

(Robert, hope you don't get tired of me saying the same thing over and over "Great work as always"...Jim )

cant agree enough!!!!!

Re: 55 Wagon Progress
 

I totally agree as well. One day this project will be finished and fabrication school will be over for us until you hopefully start and document a new project. Like I said many many posts of yours ago......just because we are not commenting doesn't mean we are not watching. Keep it coming!!

Re: 55 Wagon Progress
 

Thanks for following along fellas!


Today Mike sent time blocking out the epoxy on the sign parts and addressing any low areas. I continued working on sound deadening, have one inner quarter panel left to go..


https://i5.photobucket.com/albums/y1...7/IMG_6025.jpg


https://i5.photobucket.com/albums/y1...7/IMG_6027.jpg


https://www.youtube.com/watch?v=f-ByQZLYwRU

Re: 55 Wagon Progress
 

I'm curious on an amazing build like this what are the expectations of the owner on the time line from start to finish? I've noticed on the high end car builders TV shows the time to build can run in to several years.

Re: 55 Wagon Progress
 

She brought it to a part time shop (day job pays for family health insurance) so that comes with the distractions that go with it (and travel for the day job..) we're getting close to light at the end of the tunnel now..



Sign progress, Fine tuning of some of the parts....


https://i5.photobucket.com/albums/y1...2/IMG_6045.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6046.jpg


…..and for mounting it on the steel pole, this "shoe" is made of 14 gauge cold rolled and formed using the Go Kart slick.. The "sleeve" will slide over the pole and a set screw will hold it in place..


https://i5.photobucket.com/albums/y1...2/IMG_6048.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6049.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6050.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6051.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6052.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6053.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6054.jpg


All ready for a splash of paint...


The sound mat is installed inside the wagon...


https://www.youtube.com/watch?v=H0X0t0nT4t4






.

Re: 55 Wagon Progress
 

A couple coats of Epoxy last night to seal things up....


https://i5.photobucket.com/albums/y1...2/IMG_6056.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6057.jpg


….and then a white face added to the lighted surfaces...


https://i5.photobucket.com/albums/y1...2/IMG_6058.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6059.jpg


Then they were masked off for painting the silver....


https://i5.photobucket.com/albums/y1...2/IMG_6061.jpg


and a bit of color for the "drum"


https://i5.photobucket.com/albums/y1...2/IMG_6062.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6065.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6066.jpg


video:


https://www.youtube.com/watch?v=lPbuYB1HTTo



Now to see if Mike can get this assembled this week...

Re: 55 Wagon Progress
 

Looking good ....as always

Re: 55 Wagon Progress
 

Thanks Greg!


The sign was partially assembled today, and a test of the lights...


https://i5.photobucket.com/albums/y1...2/IMG_6072.jpg


https://i5.photobucket.com/albums/y1...2/IMG_6073.jpg


Lighting:

https://www.youtube.com/watch?v=XSX80znqiAo






.

Re: 55 Wagon Progress
 

Well the Logo has just been added, and the sign has left the building. Mike did the majority of the work on this project, I'm real pleased with how it turned out. More importantly, so is the customer!!


video:


https://www.youtube.com/watch?v=qewqepgfapc



https://i5.photobucket.com/albums/y1...2/IMG_6108.jpg

Re: 55 Wagon Progress
 

Looks great Robert!!....does it play the music also?....or is that the shop radio?

Re: 55 Wagon Progress
 

That was music we played in the shop for the occasion.. :lol: You never know what's playing over here..

Re: 55 Wagon Progress
 

Nice work!!

Re: 55 Wagon Progress
 

Very cool...Jim

Re: 55 Wagon Progress
 

I don't think there is anything you cant make out of metal. The sign is amazing!

Re: 55 Wagon Progress
 

Thanks guys!!


Time for a long overdue update. I've had too much travel for the day job since the first of the year. Case in point, we've had more than one Taco Tuesday at the Sand Bar in Cocoa Beach...


https://hosting.photobucket.com/imag...8/IMG_6479.JPG


Since completing the Drum Sign, Mike has been removing dings from the wagon's stainless trim. Here Vince and I test fit the side spears..


https://hosting.photobucket.com/imag...8/IMG_6469.JPG


https://hosting.photobucket.com/imag...8/IMG_6468.JPG


We've done some stainless repair before using small hammers and handmade punches to match the rear side of the profile, but during the last metalshaping workshop I attended at Will Cronkrite's shop in SC, I picked up a stainless dent/ding removal fixture that he had made up.. The blue sleeve at the top works on the premise of a slide hammer, with the force applied controlled by the operator. The die at the bottom (punch) is removable to allow a wide variety of specialized punches to fit the application.


https://hosting.photobucket.com/imag...8/IMG_6211.JPG


https://hosting.photobucket.com/imag...8/IMG_6213.JPG


This tool allows more controlled manipulation, especially to those of us that don't do this type of repair every day... and it's been Duallyjams tested and approved!


Here's one of the purpose built punches made for the trim...


https://hosting.photobucket.com/imag...8/IMG_6214.JPG


Here's some of our efforts in polishing out the trim after ding removal, filing, and about 6 steps of progressively finer grits of w/d and trizact….


https://hosting.photobucket.com/imag...8/IMG_6443.JPG


Reflection....


https://hosting.photobucket.com/imag...8/IMG_6445.JPG


We also were test fitting the dash trim that the owner had picked up. I know, billet is a bit played out, but let's see what works here...


https://hosting.photobucket.com/imag...8/IMG_6285.JPG


In fitting the corner pieces, the rear point of the trim does not match the unequal radius of the recess in the dash. Then when the middle (concave) radius is pushed into the recess, the rear "point" drops down out of the recess. So the underlying message here it the fit of these parts is piss poor at best.


https://hosting.photobucket.com/imag...8/IMG_6261.JPG


So we are not going to use these, but opting for something in a stainless trim.. final design TBD...


Lastly, all the travel I've had for the day job really interferes with long term efforts, paintwork in particular. So in the interest of keeping progress moving forward, we have farmed out the paintwork to Brandon and Richard Glymph at Absolute Rod and Custom Paint. So last weekend the body and various parts were delivered to their shop in Annapolis..


https://hosting.photobucket.com/imag...8/IMG_6493.JPG


So we should be doing assembly here in the near future!!

Re: 55 Wagon Progress
 

cant wait..!!!

Re: 55 Wagon Progress
 

Robert, work done to the trim is amazing. Look forward to the next update...Jim

Re: 55 Wagon Progress
 

Thanks guys!

I had a request to show more detail on the trim tool we've been using, so thought I'd share it here as well. The gentleman that made it for me advised the other day (as I had requests to see if he had more available) that he is long since retired, and anyone is more than welcome to use the details shown to make their own.



https://www.youtube.com/watch?v=Njw3X8dDRko



.

Re: 55 Wagon Progress
 

That's a nice setup Robert...I see there is a punch side..is there also a cavity side to fit what your working on..?

Re: 55 Wagon Progress
 

It's just the flat plate on the bottom. If you need a special shape or cradle to support the stainless trim it would have to be made per requirement. Although if you look in the video I have a piece of rubber that normally sits on the bottom, it's the reddish looking circle laying behind the tool on the table..