Danny Boy is BAACK! w/ '55 Big Window

[Daze57]

yo dan if ya ever make it to vegas ---------

[Dan in Pasadena]

I did final fitting/welding/grinding on the passenger side speaker holes today:

Not great after having seen some of the work you guys do but I am proud to say I id it myself. I'll get better as I go along, I'm sure of it.

I threw some primer on it just to keep it from flash rusting until I get back to it as it started raining this afternoon.


QUESTION:

Do most of you guys and girls weld all the spots, then grind everything smooth? Or do you put in a few tacks, grind, tack some more, etc?

I ground them all at the end and thought I got too much heat built up. In this case, I could NOT reach behind to hammer & dolly as I went.

[Daze57]

looks good

[Number 9]

Looks great.

[Dan in Pasadena]

Thanks you guys, but at best it looks ok. But I appreciate the kind words.

When I do the driver's door I will be even MORE careful with alignment than I already was.

[Dan in Pasadena]

Bam,
What about WHEN to grind? Seems like its easy to make the metal paper thin (Post #560 above)!

In hindsight, I tacked a moment too long. The lack of gas was effecting the weld, but I didn't know it. I was going through the flap disk too fast, so I switched to the thick grinding wheel. Worked better, but caused bluing - so I stopped immediately. Guess I gotta grind as slow as I tack, huh?

[Kabwe]

Originally Posted by Dan in Pasadena

Bam,
What about WHEN to grind? Seems like its easy to make the metal paper thin (Post #560 above)!

In hindsight, I tacked a moment too long. The lack of gas was effecting the weld, but I didn't know it. I was going through the flap disk too fast, so I switched to the thick grinding wheel. Worked better, but caused bluing - so I stopped immediately. Guess I gotta grind as slow as I tack, huh?

Dan I tack grind, tack grind, tack grind until the patch is completely welded in. Why? Because I find that this method allows me to keep the panel cool while I continue to work. Another benefit is by grinding between the tacks allows you to see where the other tacks should go once the panel is close to completion. You will not be welding on top of other welds which will also eliminate a lot of pinholes. Oh yes and if you have access to the back of the panel it also allow you to hammer on dolly as you go. Welding causes shrinkage (always) taking your time and keeping the metal cool just a allows you to keep the shrinkage to a minimum. But to truely fix all shrinkage and have to stretch the HAZ (heat affected zone - its the area that changed color during the welding process) by hammering on dolly.

Its all about how far you are willing to go. Some people like myself try to use very little to no filler, I try to get the metal that I have access to the back to only need primer as a filler. When I don't have access to the back I even more delicate when I weld in a panel because I know I will have to live with the shrinkage and use filler, so I try to minimize that shrinkage as much as possible.

I don't know what equipment you have but this is how I grind welds. I use a cut-off wheel on my 3 inch air grinder to know the bead down and then I use my roloc disc on a air grinder to clean it up and blend the patch in.

[Dan in Pasadena]

Thanks Bam, this is EXACTLY the advice I was looking for all in one place instead of reading bits & pieces in various threads and trying to surmise what's the best (for me) to do.

EQUIPMENT
I have a couple 4" angle grinders - a good Milwaukee one, and a cheapo HF one that has lasted so far. I have cut off disks and thicker grinding type disks. I'm thinking of getting a couple more angle grinders to keep a flap disk and a wire wheel on so I don't have to be changing.

I do have a cheapo air angle grinder with HF Rolocs - but since buying I've read those don't last. Have a recommendation for a good brand Roloc disk?
I also have a 60 gallon vertical compressor but I haven't run 220v to my garage yet - that is coming later this month/June.

In the meantime I have a little Senco compressor I use for tires and nailers, but it can't keep up with the angle grinder.

Thanks again for all your advice so far. Best, Dan

Originally Posted by Kabwe

Dan I tack grind, tack grind, tack grind until the patch is completely welded in. Why? Because I find that this method allows me to keep the panel cool while I continue to work. Another benefit is by grinding between the tacks allows you to see where the other tacks should go once the panel is close to completion. You will not be welding on top of other welds which will also eliminate a lot of pinholes. Oh yes and if you have access to the back of the panel it also allow you to hammer on dolly as you go. Welding causes shrinkage (always) taking your time and keeping the metal cool just a allows you to keep the shrinkage to a minimum. But to truely fix all shrinkage and have to stretch the HAZ (heat affected zone - its the area that changed color during the welding process) by hammering on dolly.

Its all about how far you are willing to go. Some people like myself try to use very little to no filler, I try to get the metal that I have access to the back to only need primer as a filler. When I don't have access to the back I even more delicate when I weld in a panel because I know I will have to live with the shrinkage and use filler, so I try to minimize that shrinkage as much as possible.

I don't know what equipment you have but this is how I grind welds. I use a cut-off wheel on my 3 inch air grinder to know the bead down and then I use my roloc disc on a air grinder to clean it up and blend the patch in.

[Kim57]

The patch came out real nice.
Kim

[Kabwe]

Dan I buy the roloc sanding disc in bulk on ebay. I buy 60 or 80 grit. Now remember I said I knock the bead down with a 3 inch cut off wheel on an air grinder. Please don't try that with your electric grind it could be bad for your health. Do the best you can until you get that compressor hooked up. I have used flap disc on electric grinder but you must be careful as you know it can remove a lot of metal. I've also used a flap disc on a variable speed polisher I liked it because I could slow the speed down.lol

[Dan in Pasadena]

Originally Posted by Kabwe

...I said I knock the bead down with a 3 inch cut off wheel on an air grinder. Please don't try that with your electric grind it could be bad for your health...

Why does it matter if the disc is powered by air or electricity in terms of my health? Seems the dust would be lousy for my lungs no matter how it got powered.

Unless you're talking about cutting myself? I ALREADY learned that painful lesson right after I got my truck and cut out an 1/8" thick plate the PO had welded into the bed. Cut the CRAP outta my index finger. Took a long time to heal that one.

[Kabwe]

Originally Posted by Dan in Pasadena

Why does it matter if the disc is powered by air or electricity in terms of my health? Seems the dust would be lousy for my lungs no matter how it got powered.

Unless you're talking about cutting myself? I ALREADY learned that painful lesson right after I got my truck and cut out an 1/8" thick plate the PO had welded into the bed. Cut the CRAP outta my index finger. Took a long time to heal that one.

Yes I'm talking about cutting yourself. Those 4 1/2 inch cut-off wheels on electric grinders are thin and will break if youvput pressure on them or cut against the grain. With the rpm's that the grinder is turning and a break man watch out it could mean big trouble.

A long time ago I was cutting and got wanted to help it along and the dang thing exploded in my hand. Well 15 stitches later I learned my lesson. I was just thankful it was my hand and not my eyes.

[mknittle]

I also use the cutoff wheels on the die grinder in tight spots where the wheel might get stuck and break or kick back. The die grinder will just stop where the electric grinder won't.

[Dan in Pasadena]

Ok, I see what you guys are talking about. There's a sort of default fail safe with the air die grinder because it will bog down. Having not really used mine yet, I didn't think of that.

On the electric grinder, it seems that the thicker grinding disc would be "safer" in that it won't slice quite as quickly if it inadvertently goes against your glove (or elsewhere/leg) than the thinner, sharper cutting disc. But I'm probably quibbling over milliseconds anyway.

[dubie]

your build thread has been a bit idle so I thought I'd check in and see how things are going Dan

[Dan in Pasadena]

Thanks for noticing.

You're right. I was on a roll and then I got sidetracked prepping for a camping. But I'm back now (again). Still a few post vacation things to do - clean/wash the camper and truck, make some repairs, etc but I should be back on the truck's door panel repairs soon so I can FINALLY!!!! paint the door interiors then get the new door weatherstripping on and stop the terrible rattling.

I rarely drive the '55 for that reason & the lack of a dual master cylinder that has me being a "Nervous Nellie" - the stock single MC only worked fine for 60 years, lol.

[Kabwe]

Dan, are you going to drive it to the Brothers Truck Show?

[Dan in Pasadena]

Meh....I don't know. She's pretty rough. Doesn't really belong out there with all those Maxim models, ha ha.

[Kabwe]

Originally Posted by Dan in Pasadena

Meh....I don't know. She's pretty rough. Doesn't really belong out there with all those Maxim models, ha ha.

Man who cares. I've seen many people drive car that are under construction. Actually some of those are the coolest ones to talk to a person about. Yeah someone always has to say something, but people always got something to say anyway. But you know how I feel about negative people who open their big mouth. They can kiss you know what. Drive your truck and enjoy it buddy. That's what its all about. Personally I would love to see it in person.

Its a classic chevy truck so it belongs.

[JR25]

Originally Posted by Kabwe

Man who cares. I've seen many people drive car that are under construction. Actually some of those are the coolest ones to talk to a person about. Yeah someone always has to say something, but people always got something to say anyway. But you know how I feel about negative people who open their big mouth. They can kiss you know what. Drive your truck and enjoy it buddy. That's what its all about. Personally I would love to see it in person.

Its a classic chevy truck so it belongs.

Right on! I always love the positive attitude you have Kawbe! Danno..... I agree, there are a lot of guys like me who would love to be able to just drive theirs around the block, you have nothing to be ashamed about. Chances are, if someone had something to say.... Either they dont even own a classic, or they didnt do any of the work on the classic that they do have!!!,
DRIVE IT MAN!!!

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[mknittle]

Originally Posted by Kabwe

Man who cares. I've seen many people drive car that are under construction. Actually some of those are the coolest ones to talk to a person about. Yeah someone always has to say something, but people always got something to say anyway. But you know how I feel about negative people who open their big mouth. They can kiss you know what. Drive your truck and enjoy it buddy. That's what its all about. Personally I would love to see it in person.

Its a classic chevy truck so it belongs.

I feel the same way. There have been a few around here that show up at events that are "under construction" I always book forward to seeing progress. And like Bam said "Actually some of those are the coolest ones to talk to a person about".

[Dan in Pasadena]

Thanks JR, Bam,

I'm not ashamed or embarrassed of my truck. I own an old truck because I love old trucks in all the ways they come from show stopper to grungy. I get a grin driving her around.

It's just that it's not "under construction" or "a build" per se. It's a refurbishment (I guess) so the frame is still 60 year old dirty - it will NOT stay that way, but you know what I mean? If it were a "build" it'd show a clean, smooth gloss or semi black frame through the unfinished bed floor, etc. I'll be at the show and I'll WANT to drive her - though it would be the longest drive she's made so far. About 80 miles round trip from Pasadena to "Anaheim" - nearly Corona out there.

Should we wear a label with our board names on it? I don't any of you guys by sight.

[Kim57]

I think it would be great if you drove it out there. I would like to see it also.
Kim

[Dan in Pasadena]

Originally Posted by Kim57

I think it would be great if you drove it out there. I would like to see it also.
Kim

Ahhhhh...the PRESSURE!

Ok, I won't promise but I'll try. Now I've gotta go home and do a few things I've been procrastinating on...you slave drivers!

[Kabwe]

Dan when I said under construction I was not talking about your truck.lol I mean really under construction. I seen guys trailer their projects to show. No engine or trans some sometimes only in bare metal displaying the work or the work that needs to be done.

Man you are light years ahead of a lot of us you can drive your truck. Enjoy it and drive it.

Its nice to see that JR25 and Kim agree. Drive the wheels off that thing.lol