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Re: 55 Wagon Progress
Speechless as always. Incredible!
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Re: 55 Wagon Progress
Keep it coming....the attention to detail is inspiring. By the way, nice welding table. dug
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Re: 55 Wagon Progress
Yeah, I'm starting to get the table filled back up again. :lol:
Another slight detour.... I need to stop looking for this stuff....or is it looking for me? This pinch weld showed swelling between the two sheets, and a closer inspection showed some rather thick scale... http://i5.photobucket.com/albums/y16...cture331-1.jpg http://i5.photobucket.com/albums/y16...cture332-1.jpg Out with the old... http://i5.photobucket.com/albums/y16...cture333-1.jpg Test fit of the new... http://i5.photobucket.com/albums/y16...cture334-1.jpg The exposed metal was media blasted, as was the inside of the newly made patch....and some epoxy primer added... http://i5.photobucket.com/albums/y16...cture335-1.jpg http://i5.photobucket.com/albums/y16...cture336-1.jpg We'll let that dry and then get it welded in place. And just to show the makeshift clamping system for cutting, grinding, and painting in an awkward spot...... http://i5.photobucket.com/albums/y16...cture337-1.jpg http://i5.photobucket.com/albums/y16...cture338-1.jpg |
Re: 55 Wagon Progress
With the epoxy well cured, holes were drilled for plug welds....
http://i5.photobucket.com/albums/y16...cture339-1.jpg Then used the modified plug weld bit for cleaning out the adjacent panel... http://i5.photobucket.com/albums/y16...cture340-1.jpg http://i5.photobucket.com/albums/y16...cture342-1.jpg http://i5.photobucket.com/albums/y16...cture343-1.jpg Cleaned spots for the plug welds... http://i5.photobucket.com/albums/y16...cture344-1.jpg http://i5.photobucket.com/albums/y16...cture345-1.jpg http://i5.photobucket.com/albums/y16...cture346-1.jpg http://i5.photobucket.com/albums/y16...cture348-1.jpg I had some questions about how well the epoxy held up to heat from welding. The epoxy next to the weld above, where it turned brown from the heat, was allowed to cool off, then attempted to scrape the paint with my thumbnail. I thought it may scrape some off, but it held tight, not so much as a scratch. Then I got on a roll and forgot pictures, but here's the patch all welded in.... http://i5.photobucket.com/albums/y16...cture349-1.jpg Next, drilled the holes in the lower window opening.... http://i5.photobucket.com/albums/y16...cture350-1.jpg .....and got the holes placed for the nut plate and it's plug welds... http://i5.photobucket.com/albums/y16...cture351-1.jpg http://i5.photobucket.com/albums/y16...cture352-1.jpg http://i5.photobucket.com/albums/y16...cture353-1.jpg Hopefully tomorrow we can get some profile blocks cut out to fold over the ends of the outer piece... |
Re: 55 Wagon Progress
Nice job. You have to hate rust.
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Re: 55 Wagon Progress
It has kept me busy! :lol:
Things don't always work the way you planned. Before the ends were folded, the bottom piece could never be test fit into the opening. Now with the ends folded, it was slipped over the bottom of the lift gate and it bolted into the opening. With the upper bead detail aligned, the lower was considerably off kilter. Slightly off on the contour, I guess. http://i5.photobucket.com/albums/y16...cture379-1.jpg http://i5.photobucket.com/albums/y16...cture380-1.jpg The patch piece was marked off on both ends to bring the lower bead detail up into the car for better alignment... http://i5.photobucket.com/albums/y16...cture381-1.jpg Here's the driver's side after cutting and welding, shows a much better alignment. Good weld penetration on the inside, the seam at the end will be finished after folding onto the lift gate.. http://i5.photobucket.com/albums/y16...cture383-1.jpg http://i5.photobucket.com/albums/y16...cture384-1.jpg http://i5.photobucket.com/albums/y16...cture385-1.jpg We may be able to save this yet.. |
Re: 55 Wagon Progress
Tricky Tricky! I had to do the same to Yeller's rockers. Boppa about had a fit when I just rammed his brand new rockers into the bandsaw! "Naw, It'll be cool."
Great stuff with that die. Do you like your Henrob? |
Re: 55 Wagon Progress
Amazing metal skills. Read and learned. Learned a lot.
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Re: 55 Wagon Progress
:jdp::jdp::jdp::jdp:<-----This icon explains better then anything I could say!!
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Re: 55 Wagon Progress
Thanks for the comments guys!
Quote:
Yes, It comes with about 6 different tips, lets you dial in the flame nicely for the job at hand. I got it quite a few years ago, think it's sold as Cobra torch now... |
Re: 55 Wagon Progress
Your mettle working skill continue to impress me!
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Re: 55 Wagon Progress
Caution: A couple of OT pictures follow, proceed at your own risk! :lol:
Sorry for my short hiatus from the shop, after 226K miles my trusty 16 year old truck has been giving me fits with transmission issues. After spending about 3 weeks on and off looking for good used trucks, the year end deals and rebates made a brand new one only slightly higher in price than a three year old model. So..... Out with the old... http://i5.photobucket.com/albums/y16...Picture366.jpg In with the new.... http://i5.photobucket.com/albums/y16...Picture401.jpg And with the truck shopping headaches behind us, we can get back in the shop ... Worked on the other end of the lower patch today, to fix the mis-alignment of the beltline trim... http://i5.photobucket.com/albums/y16...cture380-1.jpg Made a relief cut.... http://i5.photobucket.com/albums/y16...cture403-1.jpg http://i5.photobucket.com/albums/y16...cture404-1.jpg Rear view shows full weld penetration.... http://i5.photobucket.com/albums/y16...cture406-1.jpg Welds were planished, then ground to just above panel surface, and next weld overlapped, and repeat. The overlapping helps to eliminate any missed welds/pin holes. http://i5.photobucket.com/albums/y16...cture408-1.jpg http://i5.photobucket.com/albums/y16...cture409-1.jpg http://i5.photobucket.com/albums/y16...cture410-1.jpg http://i5.photobucket.com/albums/y16...cture411-1.jpg http://i5.photobucket.com/albums/y16...cture412-1.jpg http://i5.photobucket.com/albums/y16...cture413-1.jpg http://i5.photobucket.com/albums/y16...cture414-1.jpg http://i5.photobucket.com/albums/y16...cture415-1.jpg http://i5.photobucket.com/albums/y16...cture416-1.jpg http://i5.photobucket.com/albums/y16...cture417-1.jpg All done and cleaned up.... http://i5.photobucket.com/albums/y16...cture418-1.jpg http://i5.photobucket.com/albums/y16...cture419-1.jpg ......for a much better fit.. http://i5.photobucket.com/albums/y16...cture420-1.jpg Then media blasted the inside in preparation for some epoxy primer... http://i5.photobucket.com/albums/y16...Picture425.jpg .....and did some adjustment of the tailgate fitment. http://i5.photobucket.com/albums/y16...Picture422.jpg http://i5.photobucket.com/albums/y16...Picture423.jpg |
Re: 55 Wagon Progress
Nice new sled! How did you do the actual move of the trim ridge? I see the relief to go up, but how did you actually do it?
I can personally attest to the weld/grind/lap method. Helps keep the heat down, as well. Great tip. |
Re: 55 Wagon Progress
After making the relief cut, the lower folded section was placed in the vise for some "finesse" to persuade it upwards a bit. A pair of vise grips held the two together for the first tack, and after that things just fell into place.
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Re: 55 Wagon Progress
Got some B I G time skills.
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Re: 55 Wagon Progress
damn, i believe im gonna have to go get my socks, they blew off on the 1st page.
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Re: 55 Wagon Progress
Every time I check in I feel "schooled".
Amazing skillz,,,, Shouldn't there be a TOTY or something along side your name? |
Re: 55 Wagon Progress
Sometimes you just need to back up and punt.
Even though I have been working on this car far too long, with travel for the day job and two other resto's having been quite an interruption..... you get to where you finally see light at the end of the tunnel, and just come to grips with something that needs to come back out.... When I originally did this roof repair, I did not have the Lennox nibbler or English wheel or many of the tools I now have, and the patch panel you see below..... http://i5.photobucket.com/albums/y16...n/HPIM5655.jpg ....was fabricated using incremental bends in an apron brake. Given the creases you see due to the fabrication method, I likely made this shorter than I should have in an attempt to limit the creases, and the result was the horizontal weld was not up high enough to be readily accessible for planishing. After making these patch panels for a second roof repair...... http://i5.photobucket.com/albums/y16...Picture129.jpg .....it was more apparent that the first attempt was not the best, and if I wasn't happy with it before, this new panel really made the old one grab my attention...each time I've walked by. http://i5.photobucket.com/albums/y16...Picture437.jpg http://i5.photobucket.com/albums/y16...Picture438.jpg http://i5.photobucket.com/albums/y16...Picture439.jpg Well a person with spare patches lying around can only take so much, so tonight I checked the fit of one of the spare patch panels.... Looking at the front, the panel needed just a bit more crown.... http://i5.photobucket.com/albums/y16...Picture441.jpg And the rear needed just a bit less.... http://i5.photobucket.com/albums/y16...Picture446.jpg So with the Go Kart slick mounted up and ready to go, a 6" then 3.75" radius lower anvil added the crown needed for the front and a 24" radius flattened out the rear for a much better fit. http://i5.photobucket.com/albums/y16...Picture443.jpg http://i5.photobucket.com/albums/y16...Picture444.jpg http://i5.photobucket.com/albums/y16...Picture447.jpg http://i5.photobucket.com/albums/y16...Picture448.jpg http://i5.photobucket.com/albums/y16...Picture450.jpg http://i5.photobucket.com/albums/y16...Picture451.jpg http://i5.photobucket.com/albums/y16...Picture452.jpg These panels are about 4" high and put the weld up above the roof boxing structure, so planishing will be more accessible to give us a better job. I'll get the patch all primed on the inside and let it cure. Then cut out the old patch and get this new one welded in.. More to come.. |
Re: 55 Wagon Progress
Watchin
Wish I could work my English wheel half as good as you. |
Re: 55 Wagon Progress
Thanks for the generosity of your time to share these methods. Awesome!
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Re: 55 Wagon Progress
Bomp, still learning myself :lol:
Was in the middle of media blasting the innards of the lift gate and noticed the threads for these nut plates didn't look too "full" A test with a 10-24 screw showed that some of the holes were so bad that they had a "slip" fit. http://i5.photobucket.com/albums/y16...Picture453.jpg These hold the rubber bumpers on the bottom inside edge of the lift gate. The spot welds are drilled to release the nut plate.. http://i5.photobucket.com/albums/y16...Picture454.jpg http://i5.photobucket.com/albums/y16...Picture455.jpg The new ones are cut out of some 10ga steel, holes drilled and tapped. http://i5.photobucket.com/albums/y16...Picture456.jpg yeah, these threads look much better.... http://i5.photobucket.com/albums/y16...Picture457.jpg Where I normally use a couple screws to hold nut plates in place for welding, with the close proximity of the plug weld hole the screw heads would obscure some of the hole, and we would undoubtedly be welding in the screw heads for difficult removal. For this case, we'll use some brass tubing as a spacer. Since the tubing I picked up passes though the screw holes, a sacrificial lock washer is used for it's minimal diameter. http://i5.photobucket.com/albums/y16...Picture459.jpg http://i5.photobucket.com/albums/y16...Picture460.jpg A dab of anti sieze is placed on the screw threads to insure they don't get welded in place from arcing across the threads.. Plug welded, and screws removed. http://i5.photobucket.com/albums/y16...Picture461.jpg Lock washers removed and plug welds ground flush.... http://i5.photobucket.com/albums/y16...Picture463.jpg http://i5.photobucket.com/albums/y16...Picture468.jpg And now we can finish up the media blasting.... http://i5.photobucket.com/albums/y16...Picture469.jpg http://i5.photobucket.com/albums/y16...Picture470.jpg |
Re: 55 Wagon Progress
And if all looks good after your super micro inspection it's time for some primer.
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Re: 55 Wagon Progress
Can you post more details on the cutoff wheels you use? Brand, where to get them, how much longer they last than a "standard" Norton one? Thanks!
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Re: 55 Wagon Progress
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You got it! All ready for some epoxy inside! Quote:
I think if you find ones rated for stainless steel, you'll find them to last longer and to put much less of a brown cloud in the air for you to breathe. I use these by Sait: http://i5.photobucket.com/albums/y16...Picture378.jpg I get them from my local welding supply, Three Mules Welding Supply. Your local welding supply or even online sources should be able to help out. Unsure of the time frame on how long they last, but I've sure slowed down in changing them out since using the stainless rated wheels. |
Re: 55 Wagon Progress
3M Green Corps 4" discs are the BOMB! NOT cheap, but they last like iron. Unless your dumb ass drops them off the bench onto the floor. I use 'em on my air cutoff wheel. I got some pretty good ones at .035 thk for the 4 1/2" electric, name escapes me.
Beeeutiful work, as always. |
Re: 55 Wagon Progress
Yeah, I think we all have done the drop, crack, cuss! :lol:
Had a couple hours to spend in the shop this evening, so I decided to mark out the roof for re-repairing. http://i5.photobucket.com/albums/y16...Picture471.jpg Then another line was dropped down about 1/4" to be used for the "rough cut". A cutoff wheel was used and then trimmed with the snips. The lower section was trimmed about 1/2" above the drip rail.. http://i5.photobucket.com/albums/y16...Picture472.jpg To start, a section was marked off just wider than my sheet metal pliers. Then the spot welds, which were visible from the top, were drilled. A cutoff wheel was used to grind through the end(s) of the section being removed. Then the sheet metal pliers used to rock the panel back and forth to break the spot welds loose. http://i5.photobucket.com/albums/y16...Picture473.jpg http://i5.photobucket.com/albums/y16...Picture475.jpg http://i5.photobucket.com/albums/y16...Picture477.jpg Got about half of it removed, we'll save the rest for later so I can get some primer on the inside of some of the lift gate parts and the roof skin patch. http://i5.photobucket.com/albums/y16...Picture478.jpg http://i5.photobucket.com/albums/y16...Picture479.jpg http://i5.photobucket.com/albums/y16...Picture480.jpg http://i5.photobucket.com/albums/y16...Picture481.jpg http://i5.photobucket.com/albums/y16...Picture482.jpg |
Re: 55 Wagon Progress
Continuing with the dissecting of the roof.....
http://i5.photobucket.com/albums/y16...Picture483.jpg When I got into the section with the old roof, it was difficult to see the spot welds (for drilling) down inside the drip rail. The underside was more accommodating, so the face of the drip rail was marked with the sharpie to use as a reference while drilling... http://i5.photobucket.com/albums/y16...Picture484.jpg The lower corners of the opening were trimmed to size so that the roof patch could be clamped down into the drip rail. This will help to get more accurate markings on the roof skin for trimming the rest of the opening. http://i5.photobucket.com/albums/y16...Picture489.jpg http://i5.photobucket.com/albums/y16...Picture488.jpg C-Clamp vise grips added to secure the overlapped panels for marking, then a straightedge used to read the crown of the roof to insure there were no dips or puckers along the top of the joint.... http://i5.photobucket.com/albums/y16...Picture490.jpg My favorite scribe, a local auction purchase... http://i5.photobucket.com/albums/y16...Picture491.jpg Scribing the roof panel http://i5.photobucket.com/albums/y16...Picture492.jpg Not much to spare! Trimmed the opening with some offset snips... http://i5.photobucket.com/albums/y16...Picture493.jpg http://i5.photobucket.com/albums/y16...Picture494.jpg Corners touched up with a 1-1/2" drum sander http://i5.photobucket.com/albums/y16...Picture495.jpg http://i5.photobucket.com/albums/y16...Picture498.jpg Clamped in place to hold the shape while we wait for the .023 ER70S-7 to come in. Note the butt weld clamps will be removed at welding for a tight fit-up. http://i5.photobucket.com/albums/y16...Picture496.jpg http://i5.photobucket.com/albums/y16...Picture497.jpg |
Re: 55 Wagon Progress
How many vise grips do you have.
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Re: 55 Wagon Progress
Somewhere around 75 pair... when you get welding you need clamps!
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Re: 55 Wagon Progress
BOMP pointed meto this thread… and I am in debt to him! Thank you very much for sharing your work, it is :jdp:
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Re: 55 Wagon Progress
Nice fitup!
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Re: 55 Wagon Progress
Thanks for the comments guys..
Quote:
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Re: 55 Wagon Progress
Well today I had a phone call from 3 Mules to tell me the .023 welding wire was in. I had ordered .023 ER70S-7, but what actually showed up was EZ Grind. I guess I was destined to try this stuff out...
http://i5.photobucket.com/albums/y16...Picture613.jpg After about 45 minutes of changing wire, rollers, and trying different settings on the machine, we found dialing it in for 3/16 thick steel and using 1/2 second weld "application" showed about the best results.. Seems odd as the metal was 19 ga, or about .038 thick.. http://i5.photobucket.com/albums/y16...Picture614.jpg front: http://i5.photobucket.com/albums/y16...Picture615.jpg rear: http://i5.photobucket.com/albums/y16...Picture616.jpg Comparative size of the weld proud. http://i5.photobucket.com/albums/y16...Picture617.jpg http://i5.photobucket.com/albums/y16...Picture618.jpg The special made tongs had returned from Houston, so we did the spot welds first to insure the panel was pulled down into the drip rail tightly.. http://i5.photobucket.com/albums/y16...Picture622.jpg http://i5.photobucket.com/albums/y16...Picture619.jpg http://i5.photobucket.com/albums/y16...Picture621.jpg http://i5.photobucket.com/albums/y16...Picture623.jpg http://i5.photobucket.com/albums/y16...Picture625.jpg http://i5.photobucket.com/albums/y16...Picture626.jpg Then the panels were aligned and tacked, starting at the rear and working toward the front... http://i5.photobucket.com/albums/y16...Picture627.jpg http://i5.photobucket.com/albums/y16...Picture628.jpg http://i5.photobucket.com/albums/y16...Picture629.jpg Full penetration welds.... http://i5.photobucket.com/albums/y16...Picture630.jpg The patch should be well high enough for planishing this time... http://i5.photobucket.com/albums/y16...Picture631.jpg Here's where we left off..... http://i5.photobucket.com/albums/y16...Picture632.jpg http://i5.photobucket.com/albums/y16...Picture633.jpg |
Re: 55 Wagon Progress
Thank you for showing all the precision craftsmanship.
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Re: 55 Wagon Progress
MP&C. Nice job. Are you using a different nozzle on your mig gun?
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Re: 55 Wagon Progress
oops...double post
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Re: 55 Wagon Progress
The gun does have a screw in tip that is sized to the wire to keep it center, so I did change that out when I changed to the .023. Other than that, everything was the same...
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Re: 55 Wagon Progress
I understand the thread in tip is sized for 0.023 wire but what I meant was the outer nozzle. It looks like it has a step down in it like ones you can get for tig torches.
Thanks! |
Re: 55 Wagon Progress
It does have a step down feature, but that's the same and only nozzle that came with the machine over 20 years ago...
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