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Re: 55 Wagon Progress
Looks good...Jim
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Re: 55 Wagon Progress
Thanks for following along with our progress guys!
Today I was block sanding some core support parts for one more spray. Making black powder out of black epoxy primer. Not all that exciting, so I didn't take any pictures.. But wait... it gets better! Brandon and Richard have been sanding as well, only they put some color on the roof today: https://hosting.photobucket.com/imag...y/IMG_6862.JPG https://hosting.photobucket.com/imag...y/IMG_6864.JPG https://hosting.photobucket.com/imag...y/IMG_6866.JPG https://hosting.photobucket.com/imag...y/IMG_6867.JPG https://hosting.photobucket.com/imag...y/IMG_6868.JPG Clear: https://hosting.photobucket.com/imag...y/IMG_6869.JPG https://hosting.photobucket.com/imag...y/IMG_6870.JPG Can't wait for the green and some sunlight.... . |
Re: 55 Wagon Progress
That looks great..!!...ready for more...
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Re: 55 Wagon Progress
Looks super...Jim
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Re: 55 Wagon Progress
Thanks guys! Long while getting here..
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Re: 55 Wagon Progress
Some spring cleaning.... Picked up a 12" disc sander quite a few months back, and Mike has been using this on the floor.. So I decided to help the guy out and put it at a more useable height... Added a "bolting framework" to the top of one of the paint tripods, already set up with casters so you can push it in the corner....
https://hosting.photobucket.com/imag...y/IMG_6889.JPG https://hosting.photobucket.com/imag...y/IMG_6890.JPG https://hosting.photobucket.com/imag...y/IMG_6891.JPG Rivnuts installed since I didn't have bolts in stock long enough to go all the way through.. https://hosting.photobucket.com/imag...y/IMG_6892.JPG https://hosting.photobucket.com/imag...y/IMG_6893.JPG Ready for some sanding... https://hosting.photobucket.com/imag...y/IMG_6894.JPG Dana dropped off the new brake cables for the wagon the other day. The single cable that attaches to the pedal has a shouldered ferrule that sits in the bottom of the parking brake bracket. Only this shoulder was much too small for the factory hole, the Hex portion almost pulled through the hole. https://hosting.photobucket.com/imag...y/IMG_6911.JPG I considered making an adapter sleeve on the lathe, but the figured resizing the hole would be quicker. Found a nice thick 3/8 flat washer in stock that fit the ferrule shoulder perfectly and matched the thickness of the parking brake bracket. In order to get the weld heat farther from the 3/8 hole, the bracket opening was oversized up to 7/8" (largest step drill that I could find) and the washer slightly downsized to fit.. Some 3/8 standoffs made a quick arbor for the drill, and the die grinder does the rest. we had our correct size in about a minute.. https://hosting.photobucket.com/imag...y/IMG_6913.JPG https://hosting.photobucket.com/imag...y/IMG_6912.JPG https://hosting.photobucket.com/imag...y/IMG_6915.JPG Installed, much better fit... Now Vince needs to do some touch up on the paint! https://hosting.photobucket.com/imag...y/IMG_6916.JPG |
Re: 55 Wagon Progress
We're in the middle of blocking paint today on the core support and happened to notice someone forgot to add the holes in the new vertical uprights for the light wires to go across above the radiator.
https://hosting.photobucket.com/imag...y/IMG_6936.JPG We have some rotary cutters that would do the trick but they are a bit short to reach from the outside (to keep things perpendicular) so lets make an extension. The set screw for the spring loaded center point is a 5/16-24 and we happened to have some in stock. So we used a piece of stainless fuel line and plug welded a stud in one end and a plug in the other for tightening in the drill chuck.. https://hosting.photobucket.com/imag...y/IMG_6919.JPG https://hosting.photobucket.com/imag...y/IMG_6918.JPG https://hosting.photobucket.com/imag...y/IMG_6920.JPG https://hosting.photobucket.com/imag...y/IMG_6923.JPG Holes drilled, deburred, and grommet test fitted.. https://hosting.photobucket.com/imag...y/IMG_6924.JPG https://hosting.photobucket.com/imag...y/IMG_6925.JPG https://hosting.photobucket.com/imag...y/IMG_6927.JPG https://hosting.photobucket.com/imag...y/IMG_6935.JPG Now for a test fit of our Parking brake lines to mock up the routing prior to adding rivet nuts and adel clamps... https://hosting.photobucket.com/imag...y/IMG_6929.JPG https://hosting.photobucket.com/imag...y/IMG_6930.JPG https://hosting.photobucket.com/imag...y/IMG_6934.JPG https://hosting.photobucket.com/imag...y/IMG_6933.JPG And here's our one cable to two parts layout.. https://hosting.photobucket.com/imag...y/IMG_6932.JPG |
Re: 55 Wagon Progress
With our adel clamps arrived, Mike and I worked on the brake cables while Vince was prepping things for paint...
https://hosting.photobucket.com/imag...MG_6960(1).JPG https://hosting.photobucket.com/imag...MG_6984(1).JPG I think he's having too much fun... We had to wait for -5 clamps as these were snug enough to hold the cable from moving. This allows us to set the length to the backing plate such that it clears the frame during suspension travel.. https://hosting.photobucket.com/imag...y/IMG_6985.JPG The clamps were held in place using rivet nuts installed into the frame. Here is a video showing rivet nuts and the proper installation: https://www.youtube.com/watch?v=3jrrf_VbTsc https://hosting.photobucket.com/imag...y/IMG_6988.JPG Outer sheaths are marked for trimming.. https://hosting.photobucket.com/imag...y/IMG_6989.JPG Be sure to pull cables out of the way prior to cutting... https://hosting.photobucket.com/imag...y/IMG_6990.JPG Our implement of destruction... https://hosting.photobucket.com/imag...y/IMG_6991.JPG https://hosting.photobucket.com/imag...y/IMG_6992.JPG Using Gripple cutters to cut the cable... Also made by Knip-ex, both are designed for cutting steel wire rope.. https://www.youtube.com/watch?v=kWrpry0XgAU Our parking brake assembly used an integral "return spring" to pull the pedal back upwards when the brake is released, so that part is saved for this installation as well. To keep the end of the spring from rubbing against the cable in one spot, we machine a landing in the adjuster. We will also use some Teflon heat shrink over the cable to help prevent wear. https://hosting.photobucket.com/imag...y/IMG_6998.JPG Final trim on the rear cables will come when we drop the body back on the frame for proper fitment to the brake pedal assembly. https://hosting.photobucket.com/imag...y/IMG_6996.JPG . |
Re: 55 Wagon Progress
Nice! Getting Closer!
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Re: 55 Wagon Progress
That's a football field of sheet metal to work with right there! Looks superb.
Going to be beyond great and cannot wait to see it together. |
Re: 55 Wagon Progress
Guys, thanks for the comments and following along with our progress!
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Re: 55 Wagon Progress
So yeah, we work on just about anything. File this one away under "everything's a tool". You need to be able to look at the problem, and figure out what you have readily available as a solution (especially when working weekends)
Vince is still milking the media blast job.. https://hosting.photobucket.com/imag...y/IMG_7028.JPG Another of the lids had been used and abused with a hammer over it's life, the center was concaved inward, the outer rim had several flat spots. So while Vince was busy, I came up with a dent removal tool to help straighten out the next lid. https://hosting.photobucket.com/imag...y/IMG_7033.JPG https://hosting.photobucket.com/imag...y/IMG_7031.JPG https://hosting.photobucket.com/imag...y/IMG_7032.JPG The half hitch ball was used as a punch straight down into the lid to add a consistent shape back to the outer ring. Some hammer and dolly work straightened the center concave, giving it a slight crown. A deep dent was heated to make it more pliable, the punch pushed to the bottom and used as fulcrum to push the dent outward (heated spot) https://hosting.photobucket.com/imag...y/IMG_7036.JPG Then our "punch" was clamped in the vise to use as a post dolly. The lid was positioned where any low spots were placed against the "dolly" and hammering around the perimeter of the dent raised it outwards.. https://hosting.photobucket.com/imag...y/IMG_7039.JPG https://hosting.photobucket.com/imag...y/IMG_7040.JPG Some fine tuning left, but this is much better than where we started: https://www.youtube.com/watch?v=80YGom51gc0 . |
Re: 55 Wagon Progress
Innovative solution....I would have thought a trailer ball would be to hard to saw...but I never tried..
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Re: 55 Wagon Progress
Robert, nice update, super work...Jim
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Re: 55 Wagon Progress
Thanks Jim!
More progress in the shop, another upholstered piece getting assembled... this one the driver's side rear kick panel. Our polished stainless seat belt escutcheons are installed, one in the front for the lap belt and up top for the shoulder belt. https://hosting.photobucket.com/imag...MG_7286(1).JPG https://hosting.photobucket.com/imag...MG_7284(1).JPG Midrange and tweeter installed.... https://hosting.photobucket.com/imag...MG_7287(1).JPG https://www.youtube.com/watch?v=k5egWQaN1MY And we got a new "radius" fixture for the Tommasini wheeling machine, allows you to use it to form radius on flat bar and other shapes.. https://hosting.photobucket.com/imag...MG_7281(1).JPG action shot.... https://www.youtube.com/watch?v=r9e822YCYIE |
Re: 55 Wagon Progress
Those panels look great Robert..!
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Re: 55 Wagon Progress
Robert, kick panels look great, more tools, yes, yes...Jim
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Re: 55 Wagon Progress
Thanks guys!!
Overdue for another update... So with all three milk cans delivered, why not a dinner bell? Indeed. This one was missing the clapper, so that's the latest fabrication... https://hosting.photobucket.com/imag...y/IMG_7371.JPG A used 2" hitch ball was reworked in the lathe, and looks like this will be a good start... https://hosting.photobucket.com/imag...y/IMG_7366.JPG Hammer/bench head stand is used as a welding fixture.. Hey, whatever works.. https://hosting.photobucket.com/imag...y/IMG_7367.JPG root pass https://hosting.photobucket.com/imag...y/IMG_7368.JPG https://hosting.photobucket.com/imag...y/IMG_7369.JPG https://hosting.photobucket.com/imag...y/IMG_7372.JPG https://hosting.photobucket.com/imag...y/IMG_7374.JPG Finished product in action: https://www.youtube.com/watch?v=F875Q5qoVqY We had some dings in the F7 hood to remove that were located in the radius along the sides.. Didn't really have a hammer that fit the exact requirement, so I use a "KIT" that my buddy Will Cronkrite had given me, a piece cut out of a Model A leaf spring. I had more than one BF603 in stock, and rarely use the pick end, so it became the likely candidate. https://hosting.photobucket.com/imag...y/IMG_7334.JPG https://hosting.photobucket.com/imag...y/IMG_7335.JPG https://hosting.photobucket.com/imag...y/IMG_7336.JPG TIG welded in place using ER312 rod https://hosting.photobucket.com/imag...y/IMG_7340.JPG Some crown added long ways and polished up... https://hosting.photobucket.com/imag...y/IMG_7345.JPG https://hosting.photobucket.com/imag...y/IMG_7346.JPG Both of the Wagon's rear kick panels are now prepped, ready to go.. https://hosting.photobucket.com/imag...MG_7289(1).JPG https://hosting.photobucket.com/imag...y/IMG_7330.JPG Vince has the core support and associated parts blocked and ready for some green... https://hosting.photobucket.com/imag...y/IMG_7378.JPG https://hosting.photobucket.com/imag...y/IMG_7379.JPG ….and speaking of paint, we got some "new" used light fixtures for the paint booth so we can see a bit better... https://hosting.photobucket.com/imag...y/IMG_7362.JPG Old next to new... https://hosting.photobucket.com/imag...y/IMG_7347.JPG Now that we can see a bit better, it's clear that the walls need a fresh coat of white... https://hosting.photobucket.com/imag...y/IMG_7380.JPG ….And some blocking tips on the F7 hood. We have a nice crease on the inside of the hood from front to back. These scratches show that we would be taking material off the adjacent side if no other steps were taken to stop our sanding block at the center of the crease... https://hosting.photobucket.com/imag...y/IMG_7382.JPG By adding a strip of tape along the center, it gives us a positive stop for the sanding block.. https://hosting.photobucket.com/imag...y/IMG_7381.JPG Then switching for the other side.... https://hosting.photobucket.com/imag...y/IMG_7383.JPG Which leaves us a nice crease in the middle, and panels nice and flat to either side... https://hosting.photobucket.com/imag...y/IMG_7385.JPG |
Re: 55 Wagon Progress
Nice Robert ...like them old bells...
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Re: 55 Wagon Progress
Great work...Jim
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Re: 55 Wagon Progress
Some equipment changes in the shop.. The Baileigh MH19 was sold last week and Saturday morning was picked up for its journey to Pittsburgh...
https://hosting.photobucket.com/imag...y/IMG_7408.JPG After the Baileigh left, we had another louver job with Cody, this time on a C10 Chevy hood. With the Lennox sitting in the corner like this... https://hosting.photobucket.com/albu...s/IMG_4369.jpg ….. there has been a couple of occasions that large panels would run into interference with the shear. Saturday would be no exception. We had to cut the anchors with a Sawzall and slide it toward the paint booth to make room for the hood... https://hosting.photobucket.com/imag...y/IMG_7428.JPG https://hosting.photobucket.com/imag...y/IMG_7426.JPG Since the Baileigh was picked up early that morning, the spot it used to be in seemed a better location to eliminate future issues with obstructions to the side.. So we used the 6000 lb capacity engine hoist to move the approx. 4000 lbs of Lennox.. https://hosting.photobucket.com/imag...y/IMG_7433.JPG Which left this spot open for the new Powell Hammer, the replacement for the Baileigh. The dies are located higher on the new machine, so any larger panels should clear over top... https://hosting.photobucket.com/imag...y/IMG_7436.JPG Monday was moving day for the Powell hammer, Mario helped with the loading, unloading, and positioning exactly where it was supposed to go... https://hosting.photobucket.com/imag...y/IMG_7438.JPG https://hosting.photobucket.com/imag...y/IMG_7439.JPG https://hosting.photobucket.com/imag...y/IMG_7440.JPG https://hosting.photobucket.com/imag...y/IMG_7443.JPG https://hosting.photobucket.com/imag...y/IMG_7444.JPG https://hosting.photobucket.com/imag...y/IMG_7446.JPG All that's left to do is drill some holes into the concrete and add some "peg" bolts to keep things from moving around. |
Re: 55 Wagon Progress
Wow...what a piece of equipment that is...!
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Re: 55 Wagon Progress
Very nice...Jim
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Re: 55 Wagon Progress
Thanks guys!
The wagon got some paint today! Richard and Brandon Glymph of Absolute Rod and Custom Paint in Annapolis got some of the Organic green Kandy basecoat and clear sprayed. sealer: https://hosting.photobucket.com/imag...onPaint008.jpg Green: https://hosting.photobucket.com/imag...onPaint011.jpg https://hosting.photobucket.com/imag...onPaint014.jpg SPI Universal Clear: https://hosting.photobucket.com/imag...onPaint016.jpg https://hosting.photobucket.com/imag...onPaint018.jpg Video shows some of the pop you'll see in the sunlight.. https://www.youtube.com/watch?v=zfd_Dw9uyyA . |
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