1940 Packard 120 Convertible Restoration

[Advanced Design]

Oh wow...that is heartbreaking! Glad you were able to save it.

[flashed]

Wow, that really stinks about your Bug ,but you will make it all good again.

[Ol Blue K20]

I'm really sorry about your VW. If anyone can fix it properly my vote would be for you.

[swamp rat]

Bummer!! That would put an empty feeling in anybody's gut..

[plainred65]

Sorry to hear about your bug, but I feel good knowing it's going to be put back together the 'right' way.

[theastronaut]

Thanks for the comments. We worked on it Saturday to get the interior stripped out so I can pressure wash the fire extinguisher powder from all the inner panels. I can't believe how big of a mess that stuff makes.


Back to the Packard, I finished up the rear inner fender section.




Decided to start making the tail panel next. I had a spare tail panel to use as a pattern but the bottom edge was caved in.






I roughly straightened it and skimmed/blocked it to get the edge shaped up so the paper template will be accurate.

[theastronaut]

The paper template was pretty simple; there isn't much of a compound curve so the paper pretty much laid flat over the panel. I start by using magnets and tape to hold the paper in place tightly.

You can see the cut out for the bumper bracket marked, along with the edges.




The upper/outer corners had enough shape that I had to fold over a section so the paper would lay flat.




Pie cut corners to let the paper bend into the weatherstrip channel.




Some of the details are easier to add with the paper laying flat on the workbench. I measured the flange in the weatherstrip and added that line to the template with fine line tape.






The tail panel was flipped so the inner details could be added. Tape was added where there wasn't enough paper.






Blank cut out after the template was finished.

[roushinator]

Awesome work!

[Low Elco]

Looks good! Thanks for posting about the tape trick- I've used it several times in the last couple of weeks, works like a bandit! Keep up the good work!

[theastronaut]

Originally Posted by roushinator

Awesome work!

Thanks!

Originally Posted by Low Elco

Looks good! Thanks for posting about the tape trick- I've used it several times in the last couple of weeks, works like a bandit! Keep up the good work!

I'd have to find another job if I couldn't use tape. We go through tons of it.

[theastronaut]

To start the tail panel I started shaping it in the english wheel. I pulled the trunk lid out of storage so I could check the shape with a profile gague and compare it to the tail panel.






The bottom half of the tail panel I used as a template had a tighter bend starting halfway down so I only made the top half match the decklid. The bottom half was also shaped on the english wheel but I used a inner tube over the top wheel so it only rolled the metal in one direction instead of stretching the metal in two directions. I already had enough shape from side to side; the soft inner tube kept the e-wheel from stretching the metal and only added a tighter bend top to bottom.






With the overall shape finished, I tipped the top edge on the bead roller, starting with the lower edge first. I fine-tuned the edge with a hammer and t-post dolly in the vice, then stretched/shrunk the edge to match the shape of the trunk lid edge. With that edge shaped I tipped the second edge and finished folding it over with a hammer and dolly.




Added the offsets for the overlappng flanges on the bead roller.




The bottom edge was the same process as the top, tip/hammer/shrink/stretch to match the original shape. The second edge folded the opposite direction as the top, so I taped a shim to a heel dolly to make it the correct height, then folded the metal over against the dolly.

[theastronaut]

Finished panel washed with PPG cleaner/conditioner.

[flashed]

That looks good ,even your floor is clean.

[theastronaut]

Originally Posted by flashed

That looks good ,even your floor is clean.

That was the office floor, the shop floors are nearing 40 years old and aren't quite as clean!

[MP&C]

Beautiful work on the tail pan John!

[theastronaut]

Originally Posted by MP&C

Beautiful work on the tail pan John!

Thanks Robert!

[theastronaut]

Started cutting out the tail panel and trunk floor. The tail panel had been hit on the left side and poorly patched. They never even straightened the trunk floor, just left it crumpled.

[theastronaut]

With the tail panel out I had to work on saving the inner C-channel structure. This piece is made from 16 gauge with a folded lip on one side so it's pretty stiff. The passenger side is in fairly good shape but the driver side is bent pretty badly. I had to dig through all of the bondo and sheet metal that had been brazed in place to get the the spot welds that held the c-channel in place.








L/R c-channels removed.




Trunk floor cut out.






First test fit of the tail panel.

[theastronaut]

I made a quick and ugly t-post dolly to help straighten the c-channel sections.






Passenger side c-channel straightened:

[Bomp]

Quick and ugly t-post but gets the job done.

Nice work as always but what has me curious is what are you drinking in that cup?

[theastronaut]

Originally Posted by Bomp

Quick and ugly t-post but gets the job done.

Nice work as always but what has me curious is what are you drinking in that cup?

Sweet iced tea, of course.

*Posted from South Carolina*

[flashed]

Not only does your metal working skills impress me but making tools that work well too ,you do it all. I love seeing your work.

[swamp rat]

No doubt i'd be lost trying to do what you have been doing.....

[theastronaut]

Made patterns for the trunk pans yesterday.

[theastronaut]

I started on the filler neck cover while I'm waiting on new bead roller dies to dimple the trunk floor. They should be here tomorrow.

To start, I made "tucks" in the edge using a set of modified Vice-Grips that MP&C posted about in the Garage/Tool section awhile back. Hammering these out will cause the edge to shrink. The middle was stretched with a mallet and sand bag.








First quick pass through the planishing hammer to see the rough shape. Needs more stretching to raise the top still.




Made a pattern to check the shape from the original piece.