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Re: 55 Wagon Progress
Thanks Jim...
Time to make some dies for the Lennox, here fine tuning the fit.. http://i5.photobucket.com/albums/y16...ure%204482.jpg The outside corners will get some steel added for a sharper detail in the bends.. http://i5.photobucket.com/albums/y16...ure%204483.jpg The 19 ga steel is a good snug fit for the band saw cuts... http://i5.photobucket.com/albums/y16...ure%204484.jpg http://i5.photobucket.com/albums/y16...ure%204485.jpg The front edge of the panel will be tipped prior to running it through the Lennox, the tipped flange will act as a guide in the slot in the lower die.. http://i5.photobucket.com/albums/y16...ure%204491.jpg Another test run using a straight piece of scrap http://i5.photobucket.com/albums/y16...ure%204486.jpg http://i5.photobucket.com/albums/y16...ure%204488.jpg Dimensions looking much better. http://i5.photobucket.com/albums/y16...ure%204489.jpg Enough practice, starting to tip the flange on the good piece.. The tipping wheel on the bead roller bends about 30 degrees and the remaining is done manually with the hand tipping tool.. http://i5.photobucket.com/albums/y16...ure%204492.jpg http://i5.photobucket.com/albums/y16...ure%204493.jpg Flange tipped, some kick shrinking to get the right contour, and we're about ready for the Lennox.. As Kyle was off tonight we'll wait until he returns so we can have two people feeding this long piece through the machine.. http://i5.photobucket.com/albums/y16...ure%204495.jpg http://i5.photobucket.com/albums/y16...ure%204496.jpg |
Re: 55 Wagon Progress
Very nice work Robert!
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Re: 55 Wagon Progress
Nice crisp edge.
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Re: 55 Wagon Progress
Thanks guys!
As we found with some of the practice pieces, when you try to shove metal too much into a hole it tends to pull in from the edges. http://i5.photobucket.com/albums/y16...ure%204501.jpg So to fix that we'll make up a new bottom die to form the ramp fold fully, then change back to the above die to form the step.. http://i5.photobucket.com/albums/y16...ure%204500.jpg http://i5.photobucket.com/albums/y16...ure%204497.jpg The down side to using phenolic is that it gives a bit where it doesn't make sharp creases well or short reverse folds either. The initial practice pieces wouldn't fold the step down flat, so a wrap of steel was added to the top die to better persuade the step flat... http://i5.photobucket.com/albums/y16...ure%204503.jpg http://i5.photobucket.com/albums/y16...ure%204504.jpg The upper die holder helps keep the wrapped steel in place. http://i5.photobucket.com/albums/y16...ure%204505.jpg That did the trick, step is laying down nice and flat.. http://i5.photobucket.com/albums/y16...ure%204498.jpg http://i5.photobucket.com/albums/y16...ure%204499.jpg The front flange hangs over just a bit too much, some hammer action will bring it back in place. Real pleased with how well this turned out.. http://i5.photobucket.com/albums/y16...ure%204506.jpg Some of the practice scraps.. http://i5.photobucket.com/albums/y16...ure%204507.jpg |
Re: 55 Wagon Progress
Next task on the list is to add the semi-circular relief areas into the new cowl repair panel..
http://i5.photobucket.com/albums/y16...ure%204478.jpg A suitable piece of Phenolic is cut out, notched at the bottom for "vise support", and used a roloc sander and drum sander to add the relief area in the "hammer form". http://i5.photobucket.com/albums/y16...ure%204509.jpg Here's the Vise support shown in action... should remain nice and stable through all the hammer action.. http://i5.photobucket.com/albums/y16...ure%204510.jpg Centerline of the hammerform marked, as well as on the vise, to better align our new cowl.. http://i5.photobucket.com/albums/y16...ure%204511.jpg Door skin hammer will be used here to provide the radius, this one was touched up as the factory radius was a bit too large. http://i5.photobucket.com/albums/y16...ure%204512.jpg Tried it on one of our scrap pieces first.. http://i5.photobucket.com/albums/y16...ure%204513.jpg Back side.. http://i5.photobucket.com/albums/y16...ure%204517.jpg Front side and comparison to the factory version http://i5.photobucket.com/albums/y16...ure%204516.jpg http://i5.photobucket.com/albums/y16...ure%204521.jpg Action video showing the process: https://www.youtube.com/watch?v=3TawUVtIl5w |
Re: 55 Wagon Progress
Thank you for taking the time to show how to do this.
Something learned every day. |
Re: 55 Wagon Progress
Nice work...Jim
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Re: 55 Wagon Progress
Wow, good stuff. Great work as always.
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Re: 55 Wagon Progress
I think my jaw needs to be reattached to my face LOL! Nice!!
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Re: 55 Wagon Progress
Thanks for the comments guys..
A bit further along on the cowl repair.. Repair patch trimmed to size... http://i5.photobucket.com/albums/y16...ure%204522.jpg ....and then scribed to the cowl area, which gets rough cut using the 4-1/2" cut off wheel. About 1/4" excess is left for final trimming using the snips.. http://i5.photobucket.com/albums/y16...ure%204523.jpg http://i5.photobucket.com/albums/y16...ure%204524.jpg That should flow some air... http://i5.photobucket.com/albums/y16...ure%204569.jpg Tacked in place.. http://i5.photobucket.com/albums/y16...ure%204570.jpg http://i5.photobucket.com/albums/y16...ure%204571.jpg http://i5.photobucket.com/albums/y16...ure%204572.jpg |
Re: 55 Wagon Progress
That is cool, gives me hope for shaping basic patch panels. ;)
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Re: 55 Wagon Progress
As usual, very nice work...Jim
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Re: 55 Wagon Progress
Thanks Jim!
Cowl repair all complete... http://i5.photobucket.com/albums/y16...ure%204592.jpg One more thin spot from the media blasting where we had removed the leaded seam... http://i5.photobucket.com/albums/y16...ure%204593.jpg http://i5.photobucket.com/albums/y16...ure%204594.jpg Test fitting the patch for proper contour.. http://i5.photobucket.com/albums/y16...ure%204596.jpg TIG welded in place... http://i5.photobucket.com/albums/y16...ure%204597.jpg http://i5.photobucket.com/albums/y16...ure%204602.jpg Started off with some SPI epoxy on the underside... http://i5.photobucket.com/albums/y16...ure%204599.jpg ....and then the firewall http://i5.photobucket.com/albums/y16...ure%204601.jpg .....as well as the new glove box door skin... http://i5.photobucket.com/albums/y16...ure%204600.jpg The entire interior was primed by standing through the window openings... http://i5.photobucket.com/albums/y16...ure%204604.jpg http://i5.photobucket.com/albums/y16...ure%204605.jpg Then the outside was tackled... http://i5.photobucket.com/albums/y16...ure%204606.jpg http://i5.photobucket.com/albums/y16...ure%204607.jpg http://i5.photobucket.com/albums/y16...ure%204608.jpg http://i5.photobucket.com/albums/y16...ure%204609.jpg http://i5.photobucket.com/albums/y16...ure%204610.jpg |
Re: 55 Wagon Progress
Uh-oh...going to primer...I'm sure going to miss the metal working lessons! dug
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Re: 55 Wagon Progress
There may be a bit more metal work before all is said and done.. ;)
http://i5.photobucket.com/albums/y16...ure%204603.jpg Well the epoxy has cured for about three days, time to put the glove box back together... The adjacent areas are scuffed for some official door skin adhesive.. http://i5.photobucket.com/albums/y16...ure%204611.jpg ....in the form of some leftover primer from this weekend.. http://i5.photobucket.com/albums/y16...ure%204612.jpg Good thing this gets covered up... http://i5.photobucket.com/albums/y16...ure%204613.jpg Using the door skin hammer on the leather shot bag, the ends are folded first... http://i5.photobucket.com/albums/y16...ure%204616.jpg http://i5.photobucket.com/albums/y16...ure%204617.jpg http://i5.photobucket.com/albums/y16...ure%204618.jpg and then the bottom flange... http://i5.photobucket.com/albums/y16...ure%204619.jpg All together... http://i5.photobucket.com/albums/y16...ure%204620.jpg |
Re: 55 Wagon Progress
Got a "requirement" for some bead detail work and don't need the panels losing any of their shape. The bead roller does a nice job, but the forming process is more of a relocation of the metal from elsewhere, which would cause a panel to possibly lose some crown.
The Lennox (Pullmax) as a reciprocating machine does a better job of stretching the metal as the bead is formed, so there is less issue of losing panel crown. Here we're making the female die in the South Bend milling machine. http://i5.photobucket.com/albums/y16...ure%204662.jpg Ball end milling bit clamped in the chuck, square stock clamped in the Aloris tool holder.. http://i5.photobucket.com/albums/y16...ure%204664.jpg The ends of the tooling was also turned in the lathe to give a nice round feature that will work better for use with a guide. http://i5.photobucket.com/albums/y16...ure%204665.jpg http://i5.photobucket.com/albums/y16...ure%204667.jpg http://i5.photobucket.com/albums/y16...ure%204666.jpg Test run... http://i5.photobucket.com/albums/y16...ure%204668.jpg Nice crisp lines, the "chatter" should be cleaned up if I can get the feed speed more consistent. The small diameter of the upper die's "punch" provides the needed stretch, with the downside being the marking from too fast of a feed speed. Making the upper die in more of an oval shape will eliminate most of the marking, but it won't stretch as well.. To keep from losing panel crown, stretch is our preference here.. http://i5.photobucket.com/albums/y16...ure%204669.jpg This shows how well the die provides stretch, when you can add a bead in the middle of a panel.... http://i5.photobucket.com/albums/y16...ure%204672.jpg ......and there's no distortion on the ends of the bead on an otherwise flat panel.. http://i5.photobucket.com/albums/y16...ure%204674.jpg |
Re: 55 Wagon Progress
Love the Clarke Co. apron verbiage!! dug
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Re: 55 Wagon Progress
Here I thought I was the only one to blow off stuff while tig welding. lol
Thanks for showing the little hiccups along the way. Excellent bead work. |
Re: 55 Wagon Progress
Thanks for the comments guys! Not much to show on the 55, we've been block sanding, metal bumping, adding filler, lather, rinse, repeat. On the beading dies from the other night I wasn't too pleased with the shape, IMO they were too rounded. Especially for where this will be used, it needs to better match the rest of the car. So another upper die was made using a more blunt end tip with a slight ramp.
http://i5.photobucket.com/albums/y16...ure%204681.jpg The lower die was relieved to better accommodate tighter corners... http://i5.photobucket.com/albums/y16...ure%204682.jpg Comparing the two dies.... http://i5.photobucket.com/albums/y16...ure%204688.jpg Looking at the center two sample beads, the one toward the left shows a flatter bead using the new die.. http://i5.photobucket.com/albums/y16...ure%204685.jpg And on the Wheeling Machine front, I've been contemplating a storage drawer for under the base, but have struggled to find a good slide track to hold it.. Until yesterday, the guys at Dyna Rep Company came through for me, a 6" long full extension slide, in stock! Thanks Brad! http://i5.photobucket.com/albums/y16...g/IMG_1271.jpg These will be mounted between the mounting legs coming in from the side, drawer deep enough to hold all the extra lower anvils and hopefully the goKart slick... http://i5.photobucket.com/albums/y16...heel%20031.jpg |
Re: 55 Wagon Progress
Sorry I've been lax on wagon pics. When you get to the bodywork stage it doesn't show progress well. We did get another dose of SPI epoxy sprayed on the quarters today so we can better see how we're coming along..
http://i5.photobucket.com/albums/y16...ure%204722.jpg |
Re: 55 Wagon Progress
Yes, body work is one of those things that takes forever, with little results, until the paint goes on. Then it really shows....Jim
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Re: 55 Wagon Progress
Wow, that looks pretty good!
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Re: 55 Wagon Progress
Outstanding work
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Re: 55 Wagon Progress
Coming along straight as a pin.
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