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Re: 55 Wagon Progress
Back in the shop this evening, time to make some bolting brackets to hold the seat back frame to the floor..
http://i5.photobucket.com/albums/y16...5/IMG_2799.jpg Locating... http://i5.photobucket.com/albums/y16...5/IMG_2802.jpg http://i5.photobucket.com/albums/y16...5/IMG_2804.jpg Brackets TIG welded on.... http://i5.photobucket.com/albums/y16...5/IMG_2808.jpg This shows it in place, we have about 1/4" clearance at the tight spots.... https://www.youtube.com/watch?v=jB5qRfP7IxY The cleco's were removed and 1/4-20 AVK rivet nuts installed in the floor... Missed that picture... http://i5.photobucket.com/albums/y16...5/IMG_2817.jpg http://i5.photobucket.com/albums/y16...5/IMG_2818.jpg Next will be the top support.... |
Re: 55 Wagon Progress
Robert, you sure make some great pieces, love the attention to detail, that some may never see...Jim
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Re: 55 Wagon Progress
Thanks Jim!
More work on the seat back bracket... Trimming the side pieces to match the wheel well... http://i5.photobucket.com/albums/y16...5/IMG_2860.jpg Adding welding flange, hammered out of 16 gauge steel.. http://i5.photobucket.com/albums/y16...5/IMG_2864.jpg http://i5.photobucket.com/albums/y16...5/IMG_2866.jpg Test drive.... https://www.youtube.com/watch?v=mpFl01yHvKw Used the Roper Whitney hand punch to make our plug weld holes.. http://i5.photobucket.com/albums/y16...5/IMG_2871.jpg http://i5.photobucket.com/albums/y16...5/IMG_2872.jpg http://i5.photobucket.com/albums/y16...5/IMG_2873.jpg http://i5.photobucket.com/albums/y16...5/IMG_2875.jpg Next we'll close off the back area to contain the amp and bass speaker. |
Re: 55 Wagon Progress
The close up photos really do help! Thanks for posting.
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Re: 55 Wagon Progress
Impressive work on the seat frame Robert. Appreciate the documented details ... thanks for sharing.
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Re: 55 Wagon Progress
looking great, as always.
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Re: 55 Wagon Progress
Wow! I'll be stealing that square tube rounding trick! Nice stuff!
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Re: 55 Wagon Progress
Thanks for all the comments
Had a short evening in the shop as I was busy packing the neon clock for shipment, so the remainder was spent working on some of the many final details of the rear seat. Here are the factory seat clips to hold the seat bottom in place. http://i5.photobucket.com/albums/y16...5/IMG_3149.jpg http://i5.photobucket.com/albums/y16...5/IMG_3150.jpg In order to use these, let's do a sample and see if we cut a hole in some sheet metal that they'll fit into.. http://i5.photobucket.com/albums/y16...5/IMG_3145.jpg http://i5.photobucket.com/albums/y16...5/IMG_3146.jpg http://i5.photobucket.com/albums/y16...5/IMG_3147.jpg http://i5.photobucket.com/albums/y16...5/IMG_3148.jpg This looks like it will work, we'll get some 18 gauge strips made to hold these that 45 down to the floor, adding some bead details for strength.. http://i5.photobucket.com/albums/y16...5/IMG_3151.jpg |
Re: 55 Wagon Progress
Time for some brackets for the rear seat bottom retainers. Cut out some 19 gauge...
http://i5.photobucket.com/albums/y16...5/IMG_3152.jpg Drilled some holes for an inside radius, and trimmed the corners for the floor pan flange.. http://i5.photobucket.com/albums/y16...5/IMG_3154.jpg Now to fold some flanges on the sides for strength, using the Diacro press brake and a 1/2" thick lower die. By adding some rare earth magnets to the back side to serve as a back stop, we get a perfect 1/4" flange... http://i5.photobucket.com/albums/y16...5/IMG_3155.jpg http://i5.photobucket.com/albums/y16...5/IMG_3156.jpg Then some back and forth between the Erco kick shrinker and the press brake with a narrow die inside the folds.... and we have 45* bends on either end of our brackets... http://i5.photobucket.com/albums/y16...5/IMG_3157.jpg Test fit.... and trimming the retainer hole... http://i5.photobucket.com/albums/y16...5/IMG_3160.jpg http://i5.photobucket.com/albums/y16...5/IMG_3161.jpg http://i5.photobucket.com/albums/y16...5/IMG_3162.jpg http://i5.photobucket.com/albums/y16...5/IMG_3163.jpg http://i5.photobucket.com/albums/y16...5/IMG_3167.jpg http://i5.photobucket.com/albums/y16...5/IMG_3169.jpg |
Re: 55 Wagon Progress
Robert, when you make up your parts, it leaves my without any words to say, just over the top...Jim
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Re: 55 Wagon Progress
Thanks Jim!
Had our new apprentice started today, while I cut out the hole in the second seat bracket, Mike got started on punching and drilling holes for plug welding the passenger bucket seat bracket... http://i5.photobucket.com/albums/y16...5/IMG_3186.jpg http://i5.photobucket.com/albums/y16...5/IMG_3187.jpg http://i5.photobucket.com/albums/y16...5/IMG_3189.jpg After I got the bracket hole cut out, E media blasted the brackets and added some SPI epoxy using a brush. We mainly wanted to get the bottom side well covered as it will be inaccessible once welded in place.. http://i5.photobucket.com/albums/y16...5/IMG_3190.jpg http://i5.photobucket.com/albums/y16...5/IMG_3199.jpg First coat... http://i5.photobucket.com/albums/y16...5/IMG_3201.jpg Two coats, that should hold us for under a seat... http://i5.photobucket.com/albums/y16...5/IMG_3214.jpg Meanwhile I got out the John Deere rod bender to see if we could make up some anchors for the shoulder belt.. http://i5.photobucket.com/albums/y16...5/IMG_3202.jpg Bent with relief for a 1/2-13 lock nut.. http://i5.photobucket.com/albums/y16...5/IMG_3203.jpg http://i5.photobucket.com/albums/y16...5/IMG_3204.jpg Welded with short bursts and plenty of cooling between to keep the nylon lock intact.. http://i5.photobucket.com/albums/y16...5/IMG_3205.jpg test fit... http://i5.photobucket.com/albums/y16...5/IMG_3208.jpg http://i5.photobucket.com/albums/y16...5/IMG_3209.jpg plug weld holes drilled and welded in place.... http://i5.photobucket.com/albums/y16...5/IMG_3210.jpg http://i5.photobucket.com/albums/y16...5/IMG_3211.jpg Mike finished up plug welding the seat bracket in place... http://i5.photobucket.com/albums/y16...5/IMG_3213.jpg |
Re: 55 Wagon Progress
Had a late start in the shop tonight as I had to go look at a school bus. Yeah, week and a half to go until the end of school.
Looks like something gave the spot mirror a nice push.. http://i5.photobucket.com/albums/y16...0/IMG_3217.jpg http://i5.photobucket.com/albums/y16...0/IMG_3218.jpg The mirror mount looks like it's no longer straight.... http://i5.photobucket.com/albums/y16...0/IMG_3219.jpg OK, so we found it hard to fathom something hitting the mirror that high in the air as the bus was driving into it, so the other possibility was something backed into this one.. A quick search of the buses parked close by revealed this one with some nice shiny metal showing... http://i5.photobucket.com/albums/y16...0/IMG_3220.jpg http://i5.photobucket.com/albums/y16...0/IMG_3221.jpg A quick test drive showed that the mirror didn't vibrate/move around that much so we're going to address this after school is out so this one can still be used for the next couple weeks.. Back at the shop, time to weld in the seat retainer brackets... https://www.youtube.com/watch?v=o9Gj...ature=youtu.be http://i5.photobucket.com/albums/y16...5/IMG_3225.jpg http://i5.photobucket.com/albums/y16...5/IMG_3226.jpg ....and then started the next shoulder harness anchor bracket.... http://i5.photobucket.com/albums/y16...5/IMG_3233.jpg |
Re: 55 Wagon Progress
Pilot hole drilled for the passenger B-Pillar.....
http://i5.photobucket.com/albums/y16...5/IMG_3260.jpg The center point is spring loaded, but they seem to locate better using a pilot hole vs. just a punch... http://i5.photobucket.com/albums/y16...5/IMG_3261.jpg http://i5.photobucket.com/albums/y16...5/IMG_3262.jpg http://i5.photobucket.com/albums/y16...5/IMG_3263.jpg http://i5.photobucket.com/albums/y16...5/IMG_3265.jpg The plug weld holes drilled for the anchor and paint cleaned off in prep for welding.. http://i5.photobucket.com/albums/y16...5/IMG_3273.jpg Apprentice E worked on smoothing off the plug welds from last week.. http://i5.photobucket.com/albums/y16...5/IMG_3266.jpg http://i5.photobucket.com/albums/y16...5/IMG_3271.jpg Welding in the anchor ..... http://i5.photobucket.com/albums/y16...6/IMG_3281.jpg http://i5.photobucket.com/albums/y16...6/IMG_3283.jpg For the lower anchor point, which will hold both the retractor and the lap belt, we used some 14 ga that will be plug welded to the back side of the inner quarter panel just behind the B Pillar.. A 1/2" lock nut is welded to the back side, and a spacer added to the front side to keep the lap belt off the side wall. http://i5.photobucket.com/albums/y16...6/IMG_3297.jpg http://i5.photobucket.com/albums/y16...6/IMG_3298.jpg http://i5.photobucket.com/albums/y16...6/IMG_3284.jpg http://i5.photobucket.com/albums/y16...6/IMG_3285.jpg http://i5.photobucket.com/albums/y16...6/IMG_3287.jpg Or the motion picture version.... Thanks to duallyjam for stepping in for hand model duties in the video... :lol: https://www.youtube.com/watch?v=4na-...ature=youtu.be |
Re: 55 Wagon Progress
Robert, just more nice work...Jim
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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
Quote:
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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 |
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