1940 Packard 120 Convertible Restoration

[Low Elco]

Just discovered the 3" 36 grit at the new fab gig. My 11" spool of .023 ez grind is showing up today from weldingsupply.com . Good site with no hassle. If you haven't tried ez, as much as you do, GET SOME, SIR! It is the BOMB for butt welding sheet panels. Shmoove like buttah.

Hoping to start another thread, have a Duster coming for floors and trunk and quarters, etc.

You and MP&C are an inspiration. Keep it up.

[theastronaut]

Originally Posted by Advanced Design

Turn signal stalk...wow.
That pillar will be much better soon.

Yeah, it'll be fixed properly this time!

Originally Posted by Low Elco

Just discovered the 3" 36 grit at the new fab gig. My 11" spool of .023 ez grind is showing up today from weldingsupply.com . Good site with no hassle. If you haven't tried ez, as much as you do, GET SOME, SIR! It is the BOMB for butt welding sheet panels. Shmoove like buttah.

Hoping to start another thread, have a Duster coming for floors and trunk and quarters, etc.

You and MP&C are an inspiration. Keep it up.

Appreciate it! I'm using regular ER70S-6 now, been wanting to try -7 like MP&C posted about.

[theastronaut]

Built the passenger side inner A-pillar bottom today. Started by making a tape template, and fineline tape to cleanly mark the center edges where the new pieces will be welded.




Cut out new pieces from 16 gauge steel.




Shaped.






Two halves welded, and started smoothing the welds with a cutoff wheel.





Welds smoothed with a cutoff wheel, then 36 grit.




Final smoothing with 80 grit on the 3" grinder, then 60 grit on a 3" DA sander. Corners of the opening were squared up with a file.




And finished.

[flashed]

I know you get tired of hearing it but this build is just AMAZING .

[plainred65]

First place I check for updates when I log in, as always very interesting.

[Bomp]

Nice work!

[Ol Blue K20]

As usual, I'm simply amazed by your craftsmanship

[theastronaut]

Originally Posted by flashed

I know you get tired of hearing it but this build is just AMAZING .

Originally Posted by plainred65

First place I check for updates when I log in, as always very interesting.

Originally Posted by Bomp

Nice work!

Originally Posted by Ol Blue K20

As usual, I'm simply amazed by your craftsmanship

Appreciate it dudes!!


Started on getting the passenger side inner rocker in the proper location, and the inner A-pillar located.






Made templates for the rear fenderwell brace. I'll get them cut out and welded up after lunch.

[swamp rat]

Ya know i see the rusty pieces you cut out and i cant even make out some of the detail and you turn around and reproduce it. I really got to find the time to read your other threads!

[john]

Really impressed, owner picked the right man for a tough job!

[theastronaut]

Originally Posted by swamp rat

Ya know i see the rusty pieces you cut out and i cant even make out some of the detail and you turn around and reproduce it. I really got to find the time to read your other threads!

Many of the pieces are missing sections, or they've been patched so badly that I'm only guessing as to how they originally looked and fit. Having the pictures of another car really helps in those areas.

Originally Posted by john

Really impressed, owner picked the right man for a tough job!

Thanks!!



The rear fenderwell brace is finished. Made the edges fit together evenly, tacked it to hold the pieces in alignment, then welded it fully.






After smoothing the welds.

[MP&C]

Looking good John!

[Low Elco]

Awesome Possum! Really nice stuff!

[Advanced Design]

Nice detail work on the fende brace. Precise! I usually end up with gaps big enough to throw a cat through and have to start over.

[theastronaut]

Originally Posted by MP&C

Looking good John!

Originally Posted by Low Elco

Awesome Possum! Really nice stuff!

Originally Posted by Advanced Design

Nice detail work on the fende brace. Precise! I usually end up with gaps big enough to throw a cat through and have to start over.

Thanks dudes!!


Started on the A-pillar cover, needs final trimming and matching the hole sizes still.




Also started on the B-pillar bottom.







I half-rounded the mating edges on both pieces and ground the edges for a tight gap. Then did a few tacks to keep it in alignment.




Inside view.




Instead of doing a tack at a time I did a series of tacks in a row, only slightly letting off the trigger between tacks and overlapping. Seemed to make a slightly shorter weld bead and good penetration.






After smoothing the welds.

[Low Elco]

I've done the pop-pop-pop-pop tack thing, works killer if you're not like me. I seem to enjoy seeing how far I can take it, till the red spot goes "poof!" What's your trick for tipping your corner edges over? Table edge? Pliers?

[flashed]

Nice work as always ,can you give a a full shot of the car again to see where its at ? Love your attention to detail .

[theastronaut]

Originally Posted by Low Elco

I've done the pop-pop-pop-pop tack thing, works killer if you're not like me. I seem to enjoy seeing how far I can take it, till the red spot goes "poof!" What's your trick for tipping your corner edges over? Table edge? Pliers?

I like doing a series of tacks like that if its on something that won't warp easily.

Nothing special on tipping the edge, just a few different hammers and a block of steel that's older than I am. I ground each edge with a different radius, and rounded one of the corners.

Originally Posted by flashed

Nice work as always ,can you give a a full shot of the car again to see where its at ? Love your attention to detail .

Thanks flashed, here are a couple pics.

[Low Elco]

I dunno... needs more reinforcement.

[flashed]

Thanks for the pics ,it shows all your hard work and skills ,staying tuned .

[theastronaut]

Originally Posted by Low Elco

I dunno... needs more reinforcement.

I've already cut some out! It's more fun with it in anyways, watching customers in the shop try to figure out what it is.

Originally Posted by flashed

Thanks for the pics ,it shows all your hard work and skills ,staying tuned .

Thanks flashed!

[theastronaut]

Roughed in the rockers, used the bead roller to make the curved 90* edges first. I need to smooth the sharp edges on the dies, they leave marks in the metal that I dont' like. It also distorts the edge some, requiring some time on the shrinker/stretcher to make the edge straight again.






Halves matched up and clamped in place.





Tacked together, then the seam was lightly planninshed on a T-post dolly to true the edges.




Fully welded/smoothed.

[Bomp]

Super clean work, never disappointing.

Dig the extended vise grip too.

[MP&C]

Beautiful work John!

[theastronaut]

Originally Posted by Bomp

Super clean work, never disappointing.

Dig the extended vise grip too.

Originally Posted by MP&C

Beautiful work John!

Thanks!!


I reworked the front of the rocker to fit the A-pillar this morning.

Initial fit:




Scribed, and trimmed to fit the shape of the hinge pillar.






Making paper templates.






New rocker end fabbed.




Fit, welded, and smoothed.