Grizz's Redneck Express 1966 Chevy Short Fleetside RESTO-GO!

[Grizz1963]

Ahhhh Christmas break. Many parts blasted and etch primed.

Plus Photophukit playing up continually

So not much to show.

On Friday I realised that Murphy’s law meant one would run out of gas on a Saturday evening or some similar inconvenient time.

So I called to order in a spare bottle of 5% Argon/CO2

Paying a bottle deposit and gas content came to £94.00 and included home delivery on Saturday morning



Service worth paying for.

[Grizz1963]

Last bit about Christmas

I prefer a BBQ to Turkey at Christmas

Thankfully Sally and her son Ryan agreed.



So.... only coleslaw as token vegetable

The rest: Lamb Kofte Kebabs, lamb ribs, pork belly, Sweet Tai Chilli Chicken thighs, German Bratwurst, glazed Texas Pork Chops.

Yup.



Merry Christmas it certainly was.

[Grizz1963]

So.........

Cat Stevens sang “The first cut is the deepest”

Not sure if its that relevant to this truck, but once marked out, I fitted a new cutting disc and set to work cautiously



Cut through.

Then used a file to tidy up the corners and a flap disc to clean the etch primer away.



More fettling and fine tuning needed.



Everything takes time.

But got it done.



Then earthed up the front panel after practicing and lowering the power feed but increasing wire speed on some of the scrap metal.
Started tacking one spot at a time to prevent warping.



Ground back.

Holes filled, dents mostly gone, needs a skim of filler eventually



Etch primer both sides.



And all of this just to remove this bit of mess.



So that was day one.

Two hours in total, start to finish.

[Grizz1963]

Despite all sorts of good intentions, I managed less than 2 hours in the shed today.

Part was correcting my previous weld.

Then on to a few holes in the drivers side door.



Looking at the original drivers side door, specifically where the mirror was mounted, vs the new passenger door I got, that obviously used to have convoy mirrors

So I needed to ensure I welded up all the right holes.

Using both the new mirror stalk and measurements from my old door.

It has some work to do too.







Of course it has some interesting inverse dents, but nothing a hammer and dolly could not sort, with caution.



Convoy mirror mounting points.

Prepped.



Adjustable heat sink tool.

Copper pipe.



Holes plugged.



Worked back.



Etch Primer added.

.

At this point I closed shop.

Next job will be cutting some rust from the door skin and replacing with fresh metal.

Done.

[Grizz1963]

Another copy and paste on here with a couple of video clip links around metal working.

I was asked the question by a mate, and am pretty certain I have not covered it fully, so happy for anyone else to add in more to enhance the response as a resource for anyone else, who like me learns as they go along.

Originally Posted by sparkplug

So good to see truck time again :thumb2

As a complete novice welder - could you explain what the heatsink copper pipe was for?

I understand that it absorbs heat, but I don't understand why...

OK. So half your reply lies in this video.

https://youtu.be/0Iik1ftVGXI


And then some more here.


https://youtu.be/qBJwngEimZU


Half or more than half the holes and repairs on this truck will be to older holes that may have been worked before, leaving the metal thin and tired.

The copper is essentially a non stick surface where the new weld (molten steel) is laid down in order to either fill, or repair, join fresh metal.

Sheet metal is actually quite thin and the first thing that happens is that you blow holes through it, making the hole bigger when a welders amps, wire feed is not set up right. Different jobs take different settings, like most things in life.

Where old rust has eaten at the steel, it becomes fragile, like lace, with holes mixed in with thin, compromised steel in between which mostly cannot be welded up.

So you cut away the dead metal, and make and shape up a patch and weld it back in.

When heated to melting point by the weld, the metal expands and pushes (WARPS) surrounding metal.

The copper removes some of the heat fast.

I also have a copper plate, 120mm X 50mm X 6mm used for larger flat sections. As well as some bronze “round bar” part of an old shaft.

The flattened copper pipe can be shaped and bent to fit in spaces like a door window frame etc as shown.

Many places (because rust happens in tight spots often as slow evaporation and crud collection ) you cannot get in with a heat sink, so a wet rag can work, or small repeated spot welds work better.

Hence it often taking time, a lot of time to do what seems like a small job.

Practice helps with speed too. But making a shaped panel or patch adds time.

Once welded, you need to grind back, inspect, and weld again if holes appear where you did not quite get penetration or filling.

[Grizz1963]

Just to illustrate how time slips between your fingers like sand on a hot summers day on the beach the next step was to go dig out the garage vacuum cleaner.

Residual grit from the media blasting down in the bottom seam of the door plus grinder dust needed to be removed.

Followed by fine tuning the fit of the patch into the now gaping hole in my door.

Nice and it actually was.



Using my magical welding magnets, I tacked the corners and then centres.

In order to prevent warping I carried on slowly, allowing it to cool between sessions.



During this time my long suffering photographer got in from work.

So I gave her a POS mask to wear while trying to get a pic of me striking an arc.



Success.



After all the welding, I ground the welds flatter, then proceeded with a hammer and dolly, trying to reshape the corner which had been damaged at some point in the past.



Eventually, etch primer and done.



Hardly visible, and I suspect it will be a skim of filler job eventually, but two long skinny dents from the past.




That concludes the welding on the outside of the passenger door.

Next job will be the rust on the insides of the door.

Time for a rum and Pepsi Max now.

[Grizz1963]

Back to the evolution of the Galaxy.

On the way home I stopped at Just Tyres.....

The name says it all.

What it does not say, is super service, and watching the guys work with other customers made me feel good.

Service is still king.



So......

Remember they removed and disposed of the other tyres for me, so that I could refurb and paint the wheels.

Decent new tyres fitted.



Happy with the price too.



I chose not to have the the wheels fitted to,the car, as I have an appointment with @PaulY and Dr Grinder to lower the Galaxy.

This will happen another day.

So back home these will be waiting for attention.



Can’t wait to get this lot wrapped up.

.

[Grizz1963]

So it is Happy New Year day.

Last year on the 1st of January I changed the look of my 79 Blazer (now sold and in a film role)

Catscan Approved



So today I went to the garage just before 12.00 after a slow start.



After powering everything up, I added a sticker to my new mask, sent by mate Gary in Florida.



Swapped my new to me, California door for the trucks original, from California door that is so damaged.



Today’s first job was just to check out all the drilled holes from years past, mark them, weld them up.

These trucks were fixed real old Skool way, so pulling dents included holes, screws and pullers.

And after the media blasting the dents really still are there. So loads of work still to be done.

Some of the holes are quite large, and having been worked before, a lot of the steel is thin, stretched and the edges really are very thin.



So how do you fix these bloody holes ??

In my case the solution seemed obvious , thread through some 4” nails from behind, either by hand if you can find a place to get your hand and a nail in, or feed some thread, or string into the door though said hole, then attach firmly to the point of the nail and pull through and secure.

Then weld the nail in place using the head as a place to lay metal onto, and build up.

Finally, cut off the nail as flush as possible and grind back.





The track of the original dent still runs diagonally up the door and hopefully a puller and a final skim of filler would be enough there.



Finally I got all the holes in the area done.

More dents lover down, and of course a load of rust to get to next time around.



Next up would be the mirror mounting point and it’s stuck in drilled out studs and a bunch of holes on the door frame and to present it.

Seems it has convoy mirrors fitted and then they got broken off at some point, leaving more dents and holes.



But coffee, and a sandwich first, plus hand over all of Harleys stuff that was still in the house to Kevin for their cats or a cat charity.

More in a bit.

[Grizz1963]

A few years ago when I stripped the doors down, the drivers side mirror stalk screws were so tightly rusted in place that I was forced to drill out the heads, and to commit to later on adding Riv Nuts to fix the new rear view mirrors

Today I thought I would try to ease the left over studs out, using a vice grip or is that vise grip?




Success !!!



Then screwed them back in to protect the threads.

And prepped the holes to be welded.



Welded



Ground back.



Etch primer.



And done for the day.



I decided to do the door skin rust repairs another day but rather to spend time with Sally who has been good as gold.

Dinner, medium cream sherry and a fire in the lounge.

Perfect.

[Grizz1963]

Been spending the last two days trying to prepare for my year end performance review while on leave.
Not my favourite time of year.

Anyway, small lessons learned all the time.

Debenhams in Chatham are closing down and Sallys suggestion that we went to see if anything caught our eye, paid off, twice.

Got 4 work shirts and some socks valued at £114.00 for £23.00

My kinda shopping, despite two shirts being pink.

Then off to Halfords to get two more cans of etch primer.

Clever girl, suggested I look online at Evilbay for it

So........ 4x 500ml cans of UPol for £24.85 delivered vs Halfords price at £10.00 per can.

Whichever way you look at it.

Savings to be spent elsewhere.

Hope to get an hour or two in today to carry on with door skin rust repairs.

[Grizz1963]

Started very late today around 13.30 as my day was filled with stuff.

Also my last day of vacation. Back to work tomorrow, and start the year with my year end performance review at 3.30 Absolutely not looking forward to that to be honest. It was not a great year in my opinion.

Anyway, my intent was to complete door no 2’s outer door shin rust after doing all the holes before.

I am amazed at the amount of damage that has been exposed by the media blasting, dents, rust obviously and a lot more work once the new metal has been let in.

Measured, made patch no 1 and cut out the rusty part.



Fitted, magnets, welded.





Ground back.





Both doors have weird damage from below, like they have been hammered with a rock or similar tool.

A bit more hammer and dolly work needed.

But happy so far.



Then the next corner. It is the worst corner of the four in fact.

The inside is completely rotten too.

Patch ready cut, skin marked out.



Cutting out.



Nightmare.



Welded. Ground back. Not impressed.



Etch Primer done, started to pack tools back in the garage as I don’t know when next I Will get in there.



Done less than planned during my vacation, but no regrets.

As Sally said tonight when I came indoors, is there a deadline?

Nope.

Thanks for checking in.

[Grizz1963]

Just to change pace a bit, and to bring you all up to date with Dennis’ NASCAR based 1966 Chevy C10 build.

He has been busy the last few weeks.

Ultimately it will be 800+ BHP of pure Hendricks Racing motor propelling this beast down the road.



Serious stopping power.

Typical of these builds, you dream it, you build it, you tear it down, you paint it you build it and hopefully you get to drive it.



So stripping back more paint, after media blasting





On your own ??

Easy, flip it with a tractor bucket.







Progress.

Man alone, painting.








More in a bit.

Internet is not cooperating tonight

[Grizz1963]

Back to the rest of Dennis’ update pics.

NASCAR brakes on all four corners.





Typical of this sort of build, loads of parts, not one the right one.





Hand made parts too...

Turned out on the lathe.





Motor in place.

[Grizz1963]

Been chatting to Andy “Oldironfarmer” Martin as he is traveling Southward from Oregon.

Just got a status report from him as to his position.

No laughing now.



And a few more pics he has been sharing.







And the ride he picked up and is using for this trip







I think its a great road trip.

Would love to be there.

[Grizz1963]

Some more from Andy’s road trip.

Last night.








Dinner diner

[The Rocknrod]

Is that San Fransisco? Did they move Mels Diner to that place?

Originally Posted by Grizz1963

Some more from Andy’s road trip.
Last night.

Dinner diner

[Grizz1963]

So got home and found two Post Office and courier service delivery cards.

One piece next door, one next door but one.

So I fetched the etch primer from Stuart’s place.

Later just after dinner, doorbell rings madly, I know it’s Mickey.

Parcel no 2 Hand delivered.

From America, from Dennis. Sent Priority Mail, Postage $76.00

Ouch !!! And WTF??

Description is sweatshirts, but it’s a large box and it’s certainly heavier than a couple of hoodies.

So I wonder..... “Has my crazy friend Dennis rushed the lower door repair panels over to me as a random act of kindness?”

Opening the box, yup, two hoodies and some boxes wrapped inside them......l

Unpack, and it turns out to be two large boxes of my favourite Oatmeal cookies, only $1.99 a box (think postage)

Christmas card included.



P

Contents.

Red for Sally, Grey for me.




Once again gobsmacked by people’s generosity, and can only hope my pay it forward bucket is full enough to deserve this.

Life is certainly good.


PS. Had my yearly Performance Review with two managers via Skype call today.

Seems like I still have a job, and they are happy with whatever it is that I do.

It was stressing me by the way. A lot.

[Grizz1963]

Failed delivery card left today.


I would imagine it was the lowering springs.


SERIOUSLY?





Could it be a different guy?


That screws the weekend up for @PaulY and myself

[Grizz1963]

Ran the Galaxy up to the farm quickly this morning thinking there was a chance of delivery of the lowering springs today as Sally checked online.
But it seems it will be Monday as the card suggested next working day.

Took a quick side shot and 1/4 front pic so there is a baseline to compare to.





Looking forward to lowered and bigger wheels.

[Grizz1963]

Just been looking at NSane Hotrods website at cost and availability of parts to get an idea of what plan B will cost.

I am sure there are more places to look to find the parts I would love to replace with ne, but will prices differ much?

Front fenders...... $220.00 each, excludes taxes, shipping.
Rear bedsides $600.00 each, excludes tax, shipping.
Door skins $180.00 each, same rules.


Same probably for the two inner door repair panels.... not that big or heavy, just awkward.


Looks like I am doing a lot of panel work myself.


Unless I find a way to dodge someof the cost of shipping to England.


Now to try remember who offered to give stuff a ride back to the U.K. by air.

[Grizz1963]

Andy’s ongoing road trip.....


Early morning.




Remember this song??


https://youtu.be/trNW-GAClUM



.



Yup.



Guess who is there






Note the Yellow Peril hidden in the background





So the road trip continues


Unabated.

[Grizz1963]

Just been digging around on Rock Auto website.

One reproduction fender costing £90.00 or $122.00

Delivered to the UK for £281.00 or $368.00

I want to replace both the fenders outright as they are so damaged, but looking at these prices, it almost makes sense to fly out and bring them back as baggage.



They said it would be interesting.

Certainly is getting that way now.

[Grizz1963]

Just been down to the garage to check the size of a fender for someone who asked.

I am actually shocked.

Not that heavy, they are under 7kg or 15 lbs or a stone in mass


HOWEVER, I am shocked at their naked dimensions.

Approximately

56” or 1450mm long

26” or 650mm tall

8” or 200mm deep/thick.

So add a bit more for boxing up to protect from dents.

It makes sense why they get shipped as extra large or over sized parcels.

I know the rear bed sides attract a significant cost penalty too.

[Grizz1963]

Funny how things move about.


Had a question on another website an hour ago as to the weight of the fenders.

So popped to the garage to measure and weigh them.

Chatting via PM and then Whatsapp it turns out I am getting messaged from Kuala Lumpur. And it was almost midnight there.

Keeping it simple......

Messages received.


Hi Grizz
M*** (•••••••) here.
Just saw your message.
I’m a pilot with XXX and go to USA most months . I reckon I could get the fenders back as luggage if no bigger than skis .

Told him sizes again.

Reply.

For example I’m in Phoenix 23-25 January then New Orleans 22-24 February

More chat and then ended with this.

I’ve asked the question on our work Facebook group
Will get back to you when I get answers.



Lets see where this goes.

Could be helpful

[Grizz1963]

Galaxy lowering springs got delivered by my usual guy.

Looks like the instructions were from the seller.

Not impressed and will leave on feedback.