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Re: 55 Wagon Progress
Oh its getting good now! Oh second thought its so cool seeing the work that is being done. I'm torn! :lol:
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Re: 55 Wagon Progress
This evening while we had painted parts still lounging in the booth, we took some time to clean up and put tools away..... hey, there's that welding table!
http://i5.photobucket.com/albums/y16...icture1941.jpg And found a new location for the ewheel.. Still gives plenty of room for access to the parts bins and gets it out of the way elsewhere in the shop.. http://i5.photobucket.com/albums/y16...icture1942.jpg After that we worked to fix some pin holes along the passenger quarter's weld.. using a light from the back side to show the pin holes... http://i5.photobucket.com/albums/y16...icture1945.jpg http://i5.photobucket.com/albums/y16...icture1943.jpg ....and this one was a pit from the back side, more of the dreaded dirt thrown from the rear tire causing rust.... http://i5.photobucket.com/albums/y16...icture1944.jpg |
Re: 55 Wagon Progress
Great paint work there! Barry makes a good product. We used SPI on my truck.
Shop looks good and I too found my welding table again Saturday. |
Re: 55 Wagon Progress
Just found this site, lots of nice work and info. Where did you get your Gatormeet radius gauge?
Thanks Rick |
Re: 55 Wagon Progress
Robert, just found out you were on this site. I had been following you on the HAMB site, when you were doing the tailgate repairs. That was in 2013, then nothing. Glad I found you on here. Now I have to go back and read 13 pages of work, and I look forward to some great work to catch up on...Jim
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Re: 55 Wagon Progress
Thanks for the comments and questions guys!
Jim, after I got done with the tailgate, I started putting all the progress updates in one thread, "55 210 Wagon Progress", same as you see here. Thanks for following along! Rick, I got that last year while attending GatorMeet in Adamstown MD, a three-day workshop on metalshaping here on the east coast. |
Re: 55 Wagon Progress
A bit late posting the progress from yesterday.. We were supposed to finish up the passenger rear quarter, but looks like some reproduction tail light bezels are on the way. So just to be on the safe side, we'll post pone that so any final fitment will be to those parts once they get here... In the meantime, we got the primed body parts re-assembled yesterday, here installing the doors.....
http://i5.photobucket.com/albums/y16...ure%201981.jpg http://i5.photobucket.com/albums/y16...ure%201982.jpg http://i5.photobucket.com/albums/y16...ure%201983.jpg http://i5.photobucket.com/albums/y16...ure%201984.jpg http://i5.photobucket.com/albums/y16...ure%201985.jpg The SPI epoxy does a good job of providing it's own "guide coat". I blocked this with 180 grit... http://i5.photobucket.com/albums/y16...ure%201988.jpg Here's some of the low spots filled with some evercoat... http://i5.photobucket.com/albums/y16...ure%201992.jpg While I was block sanding, Kyle started modifying the hold down bracket for the battery. The post cutouts were on catty corner and didn't match todays battery posts. We had test fit the bracket on a 24F series Interstate today at Big Ed's Tires. Here's the filler piece.... http://i5.photobucket.com/albums/y16...ure%201990.jpg Shown here is the new location... http://i5.photobucket.com/albums/y16...ure%201991.jpg Filler welded in place, and the new relief cut out... http://i5.photobucket.com/albums/y16...ure%201986.jpg http://i5.photobucket.com/albums/y16...ure%201989.jpg One down, one to go... |
Re: 55 Wagon Progress
Is the jack mounted door rack something you made or is it a purchased tool? Looks like a very handy item to have.
Rick |
Re: 55 Wagon Progress
I came up with that while re-assembling the last car we finished in the shop. It' doors were quite heavy and we didn't need any paint chips....
I had seen some of the cradle style that you could add to your floor jack, but I have a problem how the cradle supports the complete weight of the door across the lower edge of a door skin. Too much risk of paint damage in my view. So I came up with another version that would support the weight across a wider area on the inner door, for less risk of damage to any visible area. Here's the basic form, with some pipe receivers using set screws. The support braces are bent from electrical EMT and covered in pipe insulation to protect the finish.. http://i5.photobucket.com/albums/y16...cture487-1.jpg http://i5.photobucket.com/albums/y16...cture488-1.jpg http://i5.photobucket.com/albums/y16...cture489-1.jpg The support braces also help to keep the door oriented in a vertical position, to keep the door from flopping back and forth (as you may experience with the cradle style). This will help prevent paint damage/chips from excessive door movement during the install. http://i5.photobucket.com/albums/y16...cture267-1.jpg http://i5.photobucket.com/albums/y16...cture269-1.jpg Notice nothing touches the edge of the door skin.... http://i5.photobucket.com/albums/y16...cture270-1.jpg http://i5.photobucket.com/albums/y16...cture271-1.jpg Once hinges are snug, loosen set screws for outer support brace, lower a couple inches, remove outer support brace, and simply pull jack toward rear of car to clear door. http://i5.photobucket.com/albums/y16...cture272-1.jpg http://i5.photobucket.com/albums/y16...cture274-1.jpg http://i5.photobucket.com/albums/y16...cture275-1.jpg |
Re: 55 Wagon Progress
Pretty slick!
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Re: 55 Wagon Progress
Nice! I hope I remember this tool the next time I take a door off a vehicle. This would save a lot of headaches.
I found your thread through another thread suggesting to read your build because you have a lot of great ideas and many of them helped. I can't remember who's thread it was or I'd give him credit. I haven't read everything yet (I'm at work...shhh, don't tell my boss I'm on here.) but from what I've seen so far, he's right. You do some nice work! |
Re: 55 Wagon Progress
The door cradle is a great idea. You should get that patented if you haven't.
Nice straight red paint too! Great approach to replacing the lead seam. Rather than cutting it out, replacing and having two weld seams to planish you will only have one seam. Cool! I agree with Duane's comment above...lots of great ideas and really nice work shared in this thread. |
Re: 55 Wagon Progress
In the past I've had guys ask what primer I was using and then why the switch to SPI, here's a home-brewed video (not mine) of a torture test on some panels sprayed with SPI... Pretty tough stuff...
https://www.youtube.com/watch?v=-yA8q4K-_Bo . |
Re: 55 Wagon Progress
Nice work, I love the detail of your metal work. You make it look so easy. Also nice work creating a special tooling to accomplish a challenge we are all faced with when adjusting doors.
Ok, here is my dumb question. I have never worked with removing lead from seams. I need to do this on two large seems across the back roof of my 53 suburban. Question - I don't have a access to an acetylene torch. Can a person heat the lead up enough using a propane torch? Thanks Marc |
Re: 55 Wagon Progress
Should be able to, just watch you don't get the heat too far away from the creases where the panel wants to warp. I normally just watch the lead. When it starts to bubble a little, brush..
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Re: 55 Wagon Progress
Tonight's update. We took delivery on some nice used core support side panels from Jay Hammond's Chevy Parts. The others were quite mangled, so this will save quite a bit of time in making a set.
http://i5.photobucket.com/albums/y16...ure%201994.jpg Kyle finishing up the battery hold down modification... http://i5.photobucket.com/albums/y16...ure%201993.jpg http://i5.photobucket.com/albums/y16...ure%201995.jpg http://i5.photobucket.com/albums/y16...ure%201996.jpg We also mocked up an MT24F battery... http://i5.photobucket.com/albums/y16...ure%201998.jpg The factory version of this battery location for an air conditioned car also calls for a "zee" bracket to the back side of the core support. http://i5.photobucket.com/albums/y16...ure%202002.jpg http://i5.photobucket.com/albums/y16...ure%201999.jpg So with dimensions taken, a practice piece was cut out of poster board... http://i5.photobucket.com/albums/y16...ure%202000.jpg http://i5.photobucket.com/albums/y16...ure%202001.jpg Laid out on some 16 GA CRS... http://i5.photobucket.com/albums/y16...ure%202004.jpg And got a bit more blocking done across the door gaps.. http://i5.photobucket.com/albums/y16...ure%202003.jpg http://i5.photobucket.com/albums/y16...ure%202006.jpg |
Re: 55 Wagon Progress
Quote:
Marc |
Re: 55 Wagon Progress
Front door gap looks great...Jim
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Re: 55 Wagon Progress
Today Kyle cut out the battery tray's zee bracket, and I had told him we should tip the top lip first and then make the vertical bends...
http://i5.photobucket.com/albums/y16...ure%202007.jpg http://i5.photobucket.com/albums/y16...ure%202008.jpg http://i5.photobucket.com/albums/y16...ure%202010.jpg As you can see, it turned out horribly, and sometimes I need a learning curve myself... :lol: We had used a narrow bottom die to tip the top flange, and should have also used something different for the vertical bends. http://i5.photobucket.com/albums/y16...ure%202015.jpg So let's back up and punt, here bending the vertical bends FIRST and using a roll former die to keep any markings to a minimum. We did a partial bend here, then did a partial tip, and jumped back and forth a few times for a much better result: http://i5.photobucket.com/albums/y16...ure%202018.jpg http://i5.photobucket.com/albums/y16...ure%202019.jpg http://i5.photobucket.com/albums/y16...ure%202020.jpg Plug welded through the thinner battery hold down into the 16 ga metal of the zee bracket using a Letter A sized holes and enough heat for weld penetration to show on the back side... http://i5.photobucket.com/albums/y16...ure%202021.jpg http://i5.photobucket.com/albums/y16...ure%202022.jpg http://i5.photobucket.com/albums/y16...ure%202023.jpg http://i5.photobucket.com/albums/y16...ure%202024.jpg Also did more fine tuning on the front end today.. http://i5.photobucket.com/albums/y16...ure%202011.jpg http://i5.photobucket.com/albums/y16...ure%202025.jpg http://i5.photobucket.com/albums/y16...ure%202026.jpg Test fit of the "early" side emblem.. http://i5.photobucket.com/albums/y16...ure%202012.jpg http://i5.photobucket.com/albums/y16...ure%202013.jpg |
Re: 55 Wagon Progress
Nice work on the zee bracket. Was it a regular tipping die / wheel you used? A small diameter one?
The gaps look great! |
Re: 55 Wagon Progress
It was using a manual tool, the one on the left here.....
http://i5.photobucket.com/albums/y16...t/_MG_9983.jpg ....that and a hammer and flat anvil clamped in the vise... |
Re: 55 Wagon Progress
Very nice detail work...Jim
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Re: 55 Wagon Progress
Thanks Jim!
We noticed the driver's side hood gap was a bit tight and then noticed a difference in the end plates on the core support. The driver's side appears bent straight, so some hammer action made them more consistent and helped out the gap issue.. http://i5.photobucket.com/albums/y16...ure%202038.jpg http://i5.photobucket.com/albums/y16...ure%202039.jpg http://i5.photobucket.com/albums/y16...ure%202040.jpg After checking the hood brace to core support for any fitment issues, we noticed some cutouts that will allow the air around the radiator. This opening, although minimal, was re-formed with a couple of fancy chisels.. http://i5.photobucket.com/albums/y16...ure%202027.jpg http://i5.photobucket.com/albums/y16...ure%202028.jpg http://i5.photobucket.com/albums/y16...ure%202029.jpg http://i5.photobucket.com/albums/y16...ure%202030.jpg http://i5.photobucket.com/albums/y16...ure%202031.jpg The excess metal ruffles were addressed easily with the kick shrinker... http://i5.photobucket.com/albums/y16...ure%202032.jpg http://i5.photobucket.com/albums/y16...ure%202033.jpg The next opening was a bit more substantial, and would require some replacement metal. Here was our first attempt at a bead along the edge of the panel.. http://i5.photobucket.com/albums/y16...ure%202036.jpg The dies would not permit quite enough length, so we used a vee die off the press brake and a 1/2" steel rod to make a radius die for the mag brake.. http://i5.photobucket.com/albums/y16...ure%202041.jpg http://i5.photobucket.com/albums/y16...ure%202042.jpg ...and between that and a straight die in the press brake, the edge bead was formed... http://i5.photobucket.com/albums/y16...ure%202045.jpg ...here transposing the crease locations... http://i5.photobucket.com/albums/y16...ure%202043.jpg http://i5.photobucket.com/albums/y16...ure%202044.jpg To pre-stretch the areas for the diagonal vee beads, we loaded these in the bead roller.... http://i5.photobucket.com/albums/y16...ure%202046.jpg http://i5.photobucket.com/albums/y16...ure%202047.jpg This didn't appear to add enough stretch, so the linear stretch die was used in the Watervliet planishing hammer.... http://i5.photobucket.com/albums/y16...ure%202048.jpg http://i5.photobucket.com/albums/y16...ure%202049.jpg Vee was added using 3/4 wide female bead die and a narrow tipping die.. http://i5.photobucket.com/albums/y16...ure%202050.jpg A bit of heat was added to make it a bit easier to transition the round and vee beads together... http://i5.photobucket.com/albums/y16...ure%202053.jpg http://i5.photobucket.com/albums/y16...ure%202054.jpg http://i5.photobucket.com/albums/y16...ure%202055.jpg http://i5.photobucket.com/albums/y16...ure%202056.jpg ....and this one we'll get formed up on Wednesday night and get both welded in place... http://i5.photobucket.com/albums/y16...ure%202057.jpg |
Re: 55 Wagon Progress
Nice update, and again some great metal work...Jim
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Re: 55 Wagon Progress
Really nice work! Was the opening to clear the radiator hose or ?
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Re: 55 Wagon Progress
For a 6 cylinder car the radiator was in front of the core support, so it was likely clearance for the top hose..
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Re: 55 Wagon Progress
Wow your metal working skills is fantastic. I like the detailed pictures of the process.
Marc |
Re: 55 Wagon Progress
Thanks Marc!
I had a bit of a short night as I had to pick up the young'n from after school activities, so most of the progress this evening was Kyle's efforts. Making the patch for the center relief, starting with adding the radius to the bottom edge... This uses a bottom vee die from the Diacro and a 1/2" rod to form the radius.. http://i5.photobucket.com/albums/y16...ure%202058.jpg http://i5.photobucket.com/albums/y16...ure%202059.jpg Test fit of the radius... http://i5.photobucket.com/albums/y16...ure%202060.jpg Trimming out the hood brace... http://i5.photobucket.com/albums/y16...ure%202061.jpg Scribing the patch.... http://i5.photobucket.com/albums/y16...ure%202064.jpg Trimming some of the excess on the bandsaw, and then fine tuning with the snips.... http://i5.photobucket.com/albums/y16...ure%202066.jpg http://i5.photobucket.com/albums/y16...ure%202067.jpg http://i5.photobucket.com/albums/y16...ure%202068.jpg I did work a bit more on hood gaps.. an official gap gauge shown here.... http://i5.photobucket.com/albums/y16...ure%202073.jpg http://i5.photobucket.com/albums/y16...ure%202075.jpg Also took some radiator leak preventative measures.... http://i5.photobucket.com/albums/y16...ure%202069.jpg http://i5.photobucket.com/albums/y16...ure%202070.jpg Trimming the other patch for the hood brace.... http://i5.photobucket.com/albums/y16...ure%202072.jpg Kyle persuading the patch's crease over a bit. This uses a glancing blow to keep the crease's new location from sliding down on the anvil... http://i5.photobucket.com/albums/y16...ure%202071.jpg Both pieces clamped in place, we'll get some welding done on Saturday... http://i5.photobucket.com/albums/y16...ure%202076.jpg |
Re: 55 Wagon Progress
Looks like Kyle is doing pretty good job.
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Re: 55 Wagon Progress
Yes, really nice work. The magnetic brake is pretty handy.
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Re: 55 Wagon Progress
Kyle is a quick learner, I think he enjoys welding especially, but we'll see this weekend how he fares with sheet metal :D
The magnetic brake does have some limitations over an apron brake, but overall it really comes in handy for radius forming and other situations where the truss of the brake would normally get in the way.. |
Re: 55 Wagon Progress
Today Kyle needed to start some welding on the hood brace, so while he was getting set up with the welder, I started making him an anvil that he could use to planish the weld dots inside the radius voids..
Heat applied... http://i5.photobucket.com/albums/y16...ure%202085.jpg http://i5.photobucket.com/albums/y16...ure%202086.jpg http://i5.photobucket.com/albums/y16...ure%202087.jpg http://i5.photobucket.com/albums/y16...ure%202090.jpg http://i5.photobucket.com/albums/y16...ure%202092.jpg http://i5.photobucket.com/albums/y16...ure%202093.jpg Kyle's first job at welding sheet metal, he's a quick learner. He did have a couple spots that didn't like the heat and blew a hole, but he did a real nice job in getting those fixed as well. http://i5.photobucket.com/albums/y16...ure%202089.jpg Planishing weld dots on the new "anvil".. http://i5.photobucket.com/albums/y16...ure%202095.jpg Full weld penetration... http://i5.photobucket.com/albums/y16...ure%202096.jpg http://i5.photobucket.com/albums/y16...ure%202097.jpg While he welded away, I turned my attention to the front end. The passenger door had a bit of a tight spot to the rear edge of the fender while opening.. Using a hack saw blade as a "feeler gauge", it was tight in one area. To help out the situation, time for another tool. I have a dent puller with a small pair of vise grips permanently attached, so we just need an adapter kit... This was some leftover square tubing scraps... http://i5.photobucket.com/albums/y16...ure%202101.jpg http://i5.photobucket.com/albums/y16...ure%202100.jpg In use.. http://i5.photobucket.com/albums/y16...ure%202102.jpg After the pulling effort, the tight gap was well over two HSB thicknesses. http://i5.photobucket.com/albums/y16...ure%202111.jpg Moving on to other fender fitment, the bottom edge of the fender was higher than the adjacent rocker. Any adjustment was futile as the bolt was at the bottom of the adjustment hole. Time for some die grinder action to bring the hole downward and also flatten the bottom edge of the hole so any movement forward or backward doesn't push the bolt upward..... This was done on both fenders.. http://i5.photobucket.com/albums/y16...ure%202112.jpg http://i5.photobucket.com/albums/y16...ure%202113.jpg http://i5.photobucket.com/albums/y16...ure%202114.jpg Test fit shows much better alignment.. This may be why the 57 went to a square hole.. http://i5.photobucket.com/albums/y16...ure%202115.jpg Kyle done with his welding on the center patch, just needs to be dressed with the sanding disc. We'll save that for after the other patch gets welded in place.. Front: http://i5.photobucket.com/albums/y16...ure%202116.jpg Rear: http://i5.photobucket.com/albums/y16...ure%202117.jpg And I was also busy making more dust... Can't wait for springtime and the leaf blower :metal: http://i5.photobucket.com/albums/y16...ure%202118.jpg http://i5.photobucket.com/albums/y16...ure%202119.jpg http://i5.photobucket.com/albums/y16...ure%202120.jpg http://i5.photobucket.com/albums/y16...ure%202121.jpg |
Re: 55 Wagon Progress
Are you keeping track of how many hours you have on this project.
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Re: 55 Wagon Progress
Yes, I got a time clock at an auction a few years back and have been keeping better track of all the projects since then. Don't have a running total right now, someone asked me about that a couple weeks ago. :lol:
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Re: 55 Wagon Progress
Someone noticed we use some rather "vintage" ice picks as scribes for metalwork, and asked to see a closer look.. I had picked these up a few years ago at an auction as my wife looks at me with that "and why do we need those" looks... The one came shorter as shown, but to prolong the life of the picks, sharpen with a very fine file, never use a grinder ;)
The auction was in Fredericksburg VA, if anyone recognizes any of the old ice plants, be sure to chime in so we can all get a history lesson. I tried calling them but nobody answered 8 or 30.. :lol: http://i5.photobucket.com/albums/y16...ure%202131.jpg http://i5.photobucket.com/albums/y16...ure%202132.jpg http://i5.photobucket.com/albums/y16...ure%202133.jpg http://i5.photobucket.com/albums/y16...ure%202134.jpg http://i5.photobucket.com/albums/y16...ure%202135.jpg http://i5.photobucket.com/albums/y16...ure%202136.jpg |
Re: 55 Wagon Progress
Thats too funny, phone 8, phone 30, thats back in the 20's era i would guess, back when every little town had a switchboard and operator to physically connect each call.
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Re: 55 Wagon Progress
Rob...Just was able to get up to date on your build...Love the metal and detail work.
Alot of cool tools in your shop!! Makes life easier for metal shaping.. Mark.. |
Re: 55 Wagon Progress
Thanks for the comments guys!
Kyle finishing up on the hood brace.... http://i5.photobucket.com/albums/y16...ure%202122.jpg http://i5.photobucket.com/albums/y16...ure%202123.jpg Because he had gaps to contend with, we used some copper to insure less chance of blow outs. A piece of 1/2" copper pipe was flattened and bent in the press brake to make a fitted backing for the vee bead detail.. http://i5.photobucket.com/albums/y16...ure%202124.jpg http://i5.photobucket.com/albums/y16...ure%202137.jpg http://i5.photobucket.com/albums/y16...ure%202142.jpg http://i5.photobucket.com/albums/y16...ure%202145.jpg http://i5.photobucket.com/albums/y16...ure%202146.jpg Just a bit of work with the sander and this part should be done. Like the new look without all the gaping holes.. Meanwhile, I continued to make dust. Here's a good view of the built in "guide coat" feature of the SPI. Blocking on the top of the hood shows a low spot..... http://i5.photobucket.com/albums/y16...ure%202140.jpg And with just a couple scuffs from the bottom, the low shows up there as well http://i5.photobucket.com/albums/y16...ure%202141.jpg Just a few bumps with the hammer from the bottom into the small shot bag on top and the low is gone. And the rest looks pretty much the same other than the piles of dust on the floor moving around.. :lol: http://i5.photobucket.com/albums/y16...ure%202139.jpg |
Re: 55 Wagon Progress
Kyle did a really nice job on the hood brace!
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