Your work looks like it was original and never touched when you're done with it. Very nice.
Printable View
Your work looks like it was original and never touched when you're done with it. Very nice.
Thanks guys!
Tonight Kyle was putting the finishing touches on prepping the passenger door for paint. Lots of nooks and crannies. We ended up moving the drill press so we could open the media blast cabinet door wide enough to put the door inside. It was a snug fit, but made easier work of cleaning the door on the ends... The rest will be done by hand...
http://i5.photobucket.com/albums/y16...icture1913.jpg
http://i5.photobucket.com/albums/y16...icture1914.jpg
After adding the radius to the doors, it only made sense that the lift gate needed the same modification. Sorry to bore you with more of the same, just wait until we get to wet sanding :D
http://i5.photobucket.com/albums/y16...icture1902.jpg
http://i5.photobucket.com/albums/y16...icture1904.jpg
Test fit the radius...
http://i5.photobucket.com/albums/y16...icture1905.jpg
Scoring the second cut location, and tacking in place..
http://i5.photobucket.com/albums/y16...icture1906.jpg
http://i5.photobucket.com/albums/y16...icture1907.jpg
http://i5.photobucket.com/albums/y16...icture1908.jpg
http://i5.photobucket.com/albums/y16...icture1909.jpg
Snapped of the excess....
http://i5.photobucket.com/albums/y16...icture1910.jpg
Checking the radius, and welded in and dressed...
http://i5.photobucket.com/albums/y16...icture1911.jpg
http://i5.photobucket.com/albums/y16...icture1912.jpg
They're calling for a heat wave this weekend (in high 40's on Sunday), so we should get some more primer sprayed....
That's one mighty fine trick alright.
Very impressed.
Great work. The heat wave will be liked by all! :LOL:
30 would be a heat wave here.
It would be night time here! :)
Kyle finishing up the prep on the door this morning, found another use for the GatorMeet radius square, here used as a sanding block to get into the tight crevices...
http://i5.photobucket.com/albums/y16...icture1915.jpg
Front fenders were both prepped with DA and 80 grit..
http://i5.photobucket.com/albums/y16...icture1917.jpg
http://i5.photobucket.com/albums/y16...icture1918.jpg
SPI Epoxy is mixed to allow for induction...
http://i5.photobucket.com/albums/y16...icture1920.jpg
http://i5.photobucket.com/albums/y16...icture1919.jpg
As the body parts had been soda blasted, it was cleaned with a hot soapy water (dish detergent) and a grey Scotchbrite, followed by a towel drying session.
http://i5.photobucket.com/albums/y16...icture1927.jpg
Then this was followed up with preclean...
http://i5.photobucket.com/albums/y16...icture1921.jpg
http://i5.photobucket.com/albums/y16...icture1922.jpg
http://i5.photobucket.com/albums/y16...icture1924.jpg
The door handle backing plates had not yet been installed on the back side of the door skins, so a coat of epoxy was sprayed on both, and then bolted together to allow to cure..
http://i5.photobucket.com/albums/y16...icture1928.jpg
http://i5.photobucket.com/albums/y16...icture1930.jpg
A good shot of the door paint fixture in action...
http://i5.photobucket.com/albums/y16...icture1936.jpg
Two coats applied...
http://i5.photobucket.com/albums/y16...icture1937.jpg
http://i5.photobucket.com/albums/y16...icture1938.jpg
http://i5.photobucket.com/albums/y16...icture1939.jpg
http://i5.photobucket.com/albums/y16...icture1940.jpg
That looks awesome! I think I may have to put the hot rod flatz on somehting else and step up and buy some spi when I ditch the purple on my 40.
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
Robert, you have inspired me and I am sure many others to try new ways of doing body repair.:) You are a jewel.:3dSMILE::3dSMILE:
Admin, please don't let anything happen to this thread.:rolleyes:;):):)
Jack.
Paint! I couldn't be more excited if it were my car.
Thanks guys, here's some more of we can't leave well enough alone.. :)
Tonight we finished up radius-ing the liftgate opening...
http://i5.photobucket.com/albums/y16...ure%201956.jpg
http://i5.photobucket.com/albums/y16...ure%201955.jpg
http://i5.photobucket.com/albums/y16...ure%201958.jpg
http://i5.photobucket.com/albums/y16...ure%201957.jpg
Next, we moved on to de-leading and shaving the last pinch weld seam at the back of the car. We've eliminated all of these to get rid of all the dirt/rust traps that we can...
http://i5.photobucket.com/albums/y16...ure%201959.jpg
http://i5.photobucket.com/albums/y16...ure%201960.jpg
http://i5.photobucket.com/albums/y16...ure%201961.jpg
http://i5.photobucket.com/albums/y16...ure%201962.jpg
Removing the excess....
http://i5.photobucket.com/albums/y16...ure%201963.jpg
http://i5.photobucket.com/albums/y16...ure%201964.jpg
http://i5.photobucket.com/albums/y16...ure%201966.jpg
Getting some gap filler.....
http://i5.photobucket.com/albums/y16...ure%201967.jpg
http://i5.photobucket.com/albums/y16...ure%201968.jpg
http://i5.photobucket.com/albums/y16...ure%201969.jpg
Flattening out the creases....
http://i5.photobucket.com/albums/y16...ure%201971.jpg
http://i5.photobucket.com/albums/y16...ure%201973.jpg
Tacked in place, and test fitting a tail light before trimming our gap filler....
http://i5.photobucket.com/albums/y16...ure%201979.jpg
http://i5.photobucket.com/albums/y16...ure%201980.jpg
....and we'll get the rest of the de-leading finished on Saturday...
Wow, that could have been a bad deal in a few years after it was painted.
Sorry I'm a little 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...
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
.
Wow! The hammer test got my attention. I might have to try that with my Summit epoxy primer using various rust treatments and washing prep! Cool!
Now take that info and a small ding like this:
http://i5.photobucket.com/albums/y16...ure%201988.jpg
.......a crowned hammer and donut dolly or small shot bag and you can get most if not all of the ding bumped out, resand, and move to the next issue.
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
Always enjoy watching the work you do, this will be one killer wagon when finished..
Thanks, we can only hope so! :D
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... :D
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
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
Great work as usual!
Rich
Ditto above
Yep.
What they said.
Great work. It's pieces like this that a real tri 5 guy will have to know aren't stock to notice something isn't right because your work looks better than factory.
Thanks fellas!
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
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 :LOL:
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
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.. :whacked:
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
Great finds. I too use some older tools in the shop. Lately at estate sales the kids and grand kids practically give away heirloom tools because they have no concept of quality or history, and probably never turned a wrench in their lives! My gain, but I always feel sad for the departed ones who spent a lifetime using and caring for these!
Great work! It's looking nice and tight! :LOL:
Thanks for the comments!
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
A while back we had made the brackets to make up three "reproduction" battery trays based on a 1955 Chevy factory air conditioned car.
http://i5.photobucket.com/albums/y16...Picture782.jpg
The only part that did not come with the used original pieces we had as patterns was the factory hold down with it's attached "zee" bracket that secures the battery hold down to the rear of the core support, as seen here in the factory assembly bulletin.
http://i5.photobucket.com/albums/y16...ure%201999.jpg
We recently mocked up the battery location, and made a zee bracket based on the picture and the dimensions we had in front of us.
http://i5.photobucket.com/albums/y16...ure%202148.jpg
http://i5.photobucket.com/albums/y16...ure%202147.jpg
Now to make the remaining two brackets for the other two battery trays.. A roll former die in the press brake was used to make the vertical bends.
http://i5.photobucket.com/albums/y16...ure%202149.jpg
A bit of tipping using a press brake die as an anvil, and then using the tipping tool...
http://i5.photobucket.com/albums/y16...ure%202150.jpg
http://i5.photobucket.com/albums/y16...ure%202151.jpg
The finished brackets and a comparison....
http://i5.photobucket.com/albums/y16...ure%202152.jpg
http://i5.photobucket.com/albums/y16...ure%202153.jpg
http://i5.photobucket.com/albums/y16...ure%202154.jpg
http://i5.photobucket.com/albums/y16...ure%202155.jpg
Not much to show on our progress today, but here's Kyle finishing up the hood brace..
http://i5.photobucket.com/albums/y16...ure%202156.jpg
http://i5.photobucket.com/albums/y16...ure%202157.jpg
http://i5.photobucket.com/albums/y16...ure%202158.jpg
While I continue to generate dust on the floor...
http://i5.photobucket.com/albums/y16...ure%202159.jpg
Recently we installed a used core support that was quite a bit nicer than our original, but still showed some issues...
http://i5.photobucket.com/albums/y16...ure%202160.jpg
Here we see some rust...
http://i5.photobucket.com/albums/y16...ure%202161.jpg
And not quite enough clearance to the petcock..
http://i5.photobucket.com/albums/y16...ure%202163.jpg
So this will be next on the list, cutting out a new one with a bit better fitment.
We had an early schedule today to try and miss the weather.. As I still hadn't finished blocking the front end, rather than pull the core support just yet, Kyle will start on the rear of the wagon in wrapping up some details there. Before pulling the tailgate, there was one gap that was inconsistent, so I gave him a hand with the rework before he got welding..
http://i5.photobucket.com/albums/y16...ure%202165.jpg
http://i5.photobucket.com/albums/y16...ure%202166.jpg
First to unfold the flange a bit...
http://i5.photobucket.com/albums/y16...ure%202168.jpg
http://i5.photobucket.com/albums/y16...ure%202167.jpg
Next, some 14 gauge steel was cut out and a strengthening bend added to use for some friendly persuasion..
http://i5.photobucket.com/albums/y16...ure%202169.jpg
http://i5.photobucket.com/albums/y16...ure%202170.jpg
Refolded...
http://i5.photobucket.com/albums/y16...ure%202172.jpg
For comparison, before:
http://i5.photobucket.com/albums/y16...ure%202166.jpg
After:
http://i5.photobucket.com/albums/y16...ure%202171.jpg
Then we tweaked the twist of the tailgate for good fitment to the opening and Kyle added three plug welds down each side to lock the skin to the inner tail gate.
http://i5.photobucket.com/albums/y16...ure%202173.jpg
http://i5.photobucket.com/albums/y16...ure%202174.jpg
...Then we removed the tail gate so he could finish the plug welds for the top flange of the tail pan, I had only tacked it in place when the tailpan was installed, so this should help check off another item from the list......
Meanwhile I continued blocking out the front end..
http://i5.photobucket.com/albums/y16...ure%202176.jpg
http://i5.photobucket.com/albums/y16...ure%202177.jpg
http://i5.photobucket.com/albums/y16...ure%202178.jpg
http://i5.photobucket.com/albums/y16...ure%202179.jpg
Nice work. Mr.Customer should love this thing.
Ms. Customer.... ;)
Well Kyle skipped out on me tonight, something about a birthday and his parents taking him out to dinner.. and here he could have been welding! :LOL:
So I took the opportunity to have dinner with the family, so tonight was a short night...
One of the other areas I skipped over at the rear of the wagon was when the tail pan was installed. The factory version with the pinch welded flanges has a gap in the crimp seam for the rear bumper seal:
http://i5.photobucket.com/albums/y16...ure%202182.jpg
As I got rid of all the pinch weld seams at the rear of the wagon to eliminate those rust traps, the gap at the crimp seam will be filled in. To assist in filling in the wide gap, a piece of copper flat bar is used as a backer..
http://i5.photobucket.com/albums/y16...ure%202184.jpg
http://i5.photobucket.com/albums/y16...ure%202185.jpg
Next, as the reproduction tail pan has a rounded crimp seam and the area on the original quarters is more of a square, we'll add some hammer action here. The remaining piece of the flat bar is clamped in and used as an anvil..
http://i5.photobucket.com/albums/y16...ure%202186.jpg
http://i5.photobucket.com/albums/y16...ure%202187.jpg
http://i5.photobucket.com/albums/y16...ure%202188.jpg
Continuing welding...
http://i5.photobucket.com/albums/y16...ure%202191.jpg
http://i5.photobucket.com/albums/y16...ure%202193.jpg
http://i5.photobucket.com/albums/y16...ure%202195.jpg
.....and a repeat on the driver's side...
http://i5.photobucket.com/albums/y16...ure%202198.jpg
http://i5.photobucket.com/albums/y16...ure%202201.jpg
http://i5.photobucket.com/albums/y16...ure%202202.jpg
Skipped out?
Well you should replace him immediately!
What say you to an old war vet with fair welding skills, 20 years experience dinking with cars as a hobby, and a bad back?
Then there'd be two of us with a bad back :LOL:
Well then, tell Kyle Happy Birthday from the gang here at CHR!
and as always thank you for sharing the pics and the lessons.