Maybe I should just paint my 40 with that. That looks pretty nice!
Printable View
Maybe I should just paint my 40 with that. That looks pretty nice!
thanks for sharing that tool with us, and as always thats some great work on the 55
Thanks guys!
Today I was block sanding some core support parts for one more spray. Making black powder out of black epoxy primer. Not all that exciting, so I didn't take any pictures.. But wait... it gets better! Brandon and Richard have been sanding as well, only they put some color on the roof today:
https://hosting.photobucket.com/imag...y/IMG_6862.JPG
https://hosting.photobucket.com/imag...y/IMG_6864.JPG
https://hosting.photobucket.com/imag...y/IMG_6866.JPG
https://hosting.photobucket.com/imag...y/IMG_6867.JPG
https://hosting.photobucket.com/imag...y/IMG_6868.JPG
Clear:
https://hosting.photobucket.com/imag...y/IMG_6869.JPG
https://hosting.photobucket.com/imag...y/IMG_6870.JPG
Can't wait for the green and some sunlight....
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Looks good!
How cool is that! Great color!
Very nice!!
Some spring cleaning.... Picked up a 12" disc sander quite a few months back, and Mike has been using this on the floor.. So I decided to help the guy out and put it at a more useable height... Added a "bolting framework" to the top of one of the paint tripods, already set up with casters so you can push it in the corner....
https://hosting.photobucket.com/imag...y/IMG_6889.JPG
https://hosting.photobucket.com/imag...y/IMG_6890.JPG
https://hosting.photobucket.com/imag...y/IMG_6891.JPG
Rivnuts installed since I didn't have bolts in stock long enough to go all the way through..
https://hosting.photobucket.com/imag...y/IMG_6892.JPG
https://hosting.photobucket.com/imag...y/IMG_6893.JPG
Ready for some sanding...
https://hosting.photobucket.com/imag...y/IMG_6894.JPG
Dana dropped off the new brake cables for the wagon the other day. The single cable that attaches to the pedal has a shouldered ferrule that sits in the bottom of the parking brake bracket. Only this shoulder was much too small for the factory hole, the Hex portion almost pulled through the hole.
https://hosting.photobucket.com/imag...y/IMG_6911.JPG
I considered making an adapter sleeve on the lathe, but the figured resizing the hole would be quicker. Found a nice thick 3/8 flat washer in stock that fit the ferrule shoulder perfectly and matched the thickness of the parking brake bracket. In order to get the weld heat farther from the 3/8 hole, the bracket opening was oversized up to 7/8" (largest step drill that I could find) and the washer slightly downsized to fit.. Some 3/8 standoffs made a quick arbor for the drill, and the die grinder does the rest. we had our correct size in about a minute..
https://hosting.photobucket.com/imag...y/IMG_6913.JPG
https://hosting.photobucket.com/imag...y/IMG_6912.JPG
https://hosting.photobucket.com/imag...y/IMG_6915.JPG
Installed, much better fit... Now Vince needs to do some touch up on the paint!
https://hosting.photobucket.com/imag...y/IMG_6916.JPG
We're in the middle of blocking paint today on the core support and happened to notice someone forgot to add the holes in the new vertical uprights for the light wires to go across above the radiator.
https://hosting.photobucket.com/imag...y/IMG_6936.JPG
We have some rotary cutters that would do the trick but they are a bit short to reach from the outside (to keep things perpendicular) so lets make an extension. The set screw for the spring loaded center point is a 5/16-24 and we happened to have some in stock. So we used a piece of stainless fuel line and plug welded a stud in one end and a plug in the other for tightening in the drill chuck..
https://hosting.photobucket.com/imag...y/IMG_6919.JPG
https://hosting.photobucket.com/imag...y/IMG_6918.JPG
https://hosting.photobucket.com/imag...y/IMG_6920.JPG
https://hosting.photobucket.com/imag...y/IMG_6923.JPG
Holes drilled, deburred, and grommet test fitted..
https://hosting.photobucket.com/imag...y/IMG_6924.JPG
https://hosting.photobucket.com/imag...y/IMG_6925.JPG
https://hosting.photobucket.com/imag...y/IMG_6927.JPG
https://hosting.photobucket.com/imag...y/IMG_6935.JPG
Now for a test fit of our Parking brake lines to mock up the routing prior to adding rivet nuts and adel clamps...
https://hosting.photobucket.com/imag...y/IMG_6929.JPG
https://hosting.photobucket.com/imag...y/IMG_6930.JPG
https://hosting.photobucket.com/imag...y/IMG_6934.JPG
https://hosting.photobucket.com/imag...y/IMG_6933.JPG
And here's our one cable to two part layout..
https://hosting.photobucket.com/imag...y/IMG_6932.JPG
With our adel clamps arrived, Mike and I worked on the brake cables while Vince was prepping things for paint...
https://hosting.photobucket.com/imag...MG_6960(1).JPG
https://hosting.photobucket.com/imag...MG_6984(1).JPG
I think he's having too much fun...
We had to wait for -5 clamps as these were snug enough to hold the cable from moving. This allows us to set the length to the backing plate such that it clears the frame during suspension travel..
https://hosting.photobucket.com/imag...y/IMG_6985.JPG
The clamps were held in place using rivet nuts installed into the frame. Here is a video showing rivet nuts and the proper installation:
https://www.youtube.com/watch?v=3jrrf_VbTsc
https://hosting.photobucket.com/imag...y/IMG_6988.JPG
Outer sheaths are marked for trimming..
https://hosting.photobucket.com/imag...y/IMG_6989.JPG
Be sure to pull cables out of the way prior to cutting...
https://hosting.photobucket.com/imag...y/IMG_6990.JPG
Our implement of destruction...
https://hosting.photobucket.com/imag...y/IMG_6991.JPG
https://hosting.photobucket.com/imag...y/IMG_6992.JPG
Using Gripple cutters to cut the cable... Also made by Knip-ex, both are designed for cutting steel wire rope..
https://www.youtube.com/watch?v=kWrpry0XgAU
Our parking brake assembly used an integral "return spring" to pull the pedal back upwards when the brake is released, so that part is saved for this installation as well. To keep the end of the spring from rubbing against the cable in one spot, we machine a landing in the adjuster. We will also use some Teflon heat shrink over the cable to help prevent wear.
https://hosting.photobucket.com/imag...y/IMG_6998.JPG
Final trim on the rear cables will come when we drop the body back on the frame for proper fitment to the brake pedal assembly.
https://hosting.photobucket.com/imag...y/IMG_6996.JPG
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That looks very nice!
Had a visitor in the shop yesterday, collaborating with Cody Walls of Traditional Metalcraft (Milton, DE) on adding some louvers to an Austin Healey project he has in his shop. We got the bonnet done yesterday, and I had to modify my radius fixture for the boot as it had too much crown to simply louver while flat. So that is yet to come.
https://hosting.photobucket.com/imag...y/IMG_7009.JPG
Time lapse:
https://www.youtube.com/watch?v=Y0zjX58BDgM
https://hosting.photobucket.com/imag...y/IMG_7011.JPG
https://hosting.photobucket.com/imag...y/IMG_7012.JPG
Modifying our radius fixture for louvering the boot:
https://www.youtube.com/watch?v=2_0rl50XxzM
Here's pictures of the project car in Cody's shop for reference. Photo credit Traditional Metalcraft. Follow the progress on his build @eastcoastchanneljob on IG or Traditional Metalcraft on FB. This car is sporting a Honda S2000 drivetrain, should be a handful..
https://hosting.photobucket.com/imag.../IMG_7005a.jpg
https://hosting.photobucket.com/imag.../IMG_7005b.jpg
Those louvers are fantastic. Prepping, painting, and polishing them...………...that's another matter. Fortunately not yours.....:)
Bob, Cody says this one is keeping its bare finish, all aluminum.. But I'm with you.. We did go through a bit of practice samples and adjustment on the dies to minimize any burrs, but you still get them.. Previously we had riveted the "stop angles" to the skin and relied on filling holes. Since this will be bare aluminum, we figured any welds would be more visible, so the internal frame stop device was made, its screwed to the outer flange where things will be less noticeable..
So yeah, we work on just about anything. File this one away under "everything's a tool". You need to be able to look at the problem, and figure out what you have readily available as a solution (especially when working weekends)
Vince is still milking the media blast job..
https://hosting.photobucket.com/imag...y/IMG_7028.JPG
Another of the lids had been used and abused with a hammer over it's life, the center was concaved inward, the outer rim had several flat spots. So while Vince was busy, I came up with a dent removal tool to help straighten out the next lid.
https://hosting.photobucket.com/imag...y/IMG_7033.JPG
https://hosting.photobucket.com/imag...y/IMG_7031.JPG
https://hosting.photobucket.com/imag...y/IMG_7032.JPG
The half hitch ball was used as a punch straight down into the lid to add a consistent shape back to the outer ring. Some hammer and dolly work straightened the center concave, giving it a slight crown. A deep dent was heated to make it more pliable, the punch pushed to the bottom and used as fulcrum to push the dent outward (heated spot)
https://hosting.photobucket.com/imag...y/IMG_7036.JPG
Then our "punch" was clamped in the vise to use as a post dolly. The lid was positioned where any low spots were placed against the "dolly" and hammering around the perimeter of the dent raised it outwards..
https://hosting.photobucket.com/imag...y/IMG_7039.JPG
https://hosting.photobucket.com/imag...y/IMG_7040.JPG
Some fine tuning left, but this is much better than where we started:
https://www.youtube.com/watch?v=80YGom51gc0
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Words fail me.
That is bloody clever.
Thanks John!
Cody set the hood (bonnet) on the Austin Healey to get a look see on the louvers....
https://hosting.photobucket.com/imag...y/IMG_7154.JPG
…..and this past Tuesday he came back to the shop so we could finish up the louvers in the trunk lid (boot). I must say this was the most involved and challenging louver job we have done so far. The trunk lid has a lot of crown, and with a 6” rise in the center, we needed to use the rotation fixture ala Mini Cooper wheel hub. We added to this a hinge mechanism to allow rotation up and down. The limits of the machine's throat height and high crown also meant we'd have to punch half the louvers from back end first, then rotate the lid and tooling and approach the rest from the front end. Now given the extreme flex/twist that the .050 aluminum is prone to, we needed to make sure the cut pattern would be parallel to the last set at the point we rotated from front to back. This required some "gusset" straps clamped in place to limit the twist.
https://hosting.photobucket.com/imag...y/IMG_7119.JPG
Before this was added, any twist of the panel would change the outer limits of the cut +/- 1/4". Here's the wheel hub arrangement along with the hinges for up and down adjustment. We needed adjustments along 3 different axis to be able keep all the louvers running true and parallel.
https://hosting.photobucket.com/imag...y/IMG_7125.JPG
https://hosting.photobucket.com/imag...y/IMG_7124.JPG
….and we're off....
https://hosting.photobucket.com/imag...y/IMG_7126.JPG
At this point we were 4 hours in to measuring, clamping, test run (drag the cutter against the panel to scribe the location), rotate 180 front to back, and test the pattern again, just to get to where we could start cutting. …..and another 4 hours to go before we finished. All told, with the time Vince and I spent Saturday working out clamping methods and other details, the layout was approx 4 times that of what it took to do the actual cutting.
https://hosting.photobucket.com/imag...y/IMG_7149.JPG
https://hosting.photobucket.com/imag...y/IMG_7150.JPG
https://hosting.photobucket.com/imag...y/IMG_7152.JPG
….and the time lapse video of the process..
https://www.youtube.com/watch?v=NMmm...ature=youtu.be
https://hosting.photobucket.com/imag...y/IMG_7130.JPG
https://hosting.photobucket.com/imag...y/IMG_7139.JPG
Yesterday Cody sent me pictures of the trunk lid installed.. These louvers really change the attitude of the car... Badass....
https://hosting.photobucket.com/imag...y/IMG_7157.JPG
https://hosting.photobucket.com/imag...y/IMG_7158.JPG
https://hosting.photobucket.com/imag...y/IMG_7154.JPG
hard to say anything more than WOW
What Charlie said!
Although, the suitcases might get wet if it rains...…….
Thanks guys! Cody has an inner lid fabricated so they can have the look of louvers and any rain should drain to the bottom
I'm familiar with Austin Healeys, a mate of mine owned one some years back, ridden in it lots and lots, and put 'essential supplies' (beer,) in the boot (trunk,) many times.
Until I saw that photograph I had never noticed that the boot hinges are standard Morris Minor 1000.
Never too old to learn huh?
And yeah, I too can only repeat Charlie and Uncle Bob's 'WOW!'
I got out of school in '76 and moved to KC to work, and I would go through the KC Times Sunday paper classifieds looking for "deals". I remember looking at '67 Fastback Mustangs for $1800 and saying to myself "You can't pay $1800 for a car that's 10 years old and only cost $3000!"; and I always scrolled through the "Imported" section looking for an Austin Healey 3000! Like the Mustangs, I'd see one for $1200 or $1500 and scoff at it, thinking they were asking crazy money! Oh to have that "Way Back Machine" today......
You're doing some fantastic work on this Healey! Looking forward to seeing it complete!
Thanks for the comments guys! Always fun to take a day for louvers!
Time to play catch up here..
Vince got two of the milk cans media blasted and worked on the third while I sprayed some SPI epoxy primer on the first two.
https://hosting.photobucket.com/imag...y/IMG_7212.JPG
https://hosting.photobucket.com/imag...y/IMG_7213.JPG
Also got some epoxy on the hood brace...
https://hosting.photobucket.com/imag...y/IMG_7211.JPG
Ends are quite a bit better than before..
https://hosting.photobucket.com/imag...y/IMG_7210.JPG
https://hosting.photobucket.com/imag...y/IMG_7209.JPG
I received a state of the art drawing the other day, and was asked if we could duplicate the 1/16 offset shown...
https://hosting.photobucket.com/imag...y/IMG_7221.PNG
Of course this meant we needed some new tooling..
https://hosting.photobucket.com/imag...y/IMG_7222.JPG
https://hosting.photobucket.com/imag...y/IMG_7223.JPG
https://hosting.photobucket.com/imag...y/IMG_7237.JPG
Our first sample, with the proper 3/4 flange...
https://hosting.photobucket.com/imag...y/IMG_7234.JPG
https://hosting.photobucket.com/imag...y/IMG_7235.JPG
https://hosting.photobucket.com/imag...y/IMG_7238.JPG
We had another panel that would require the offset on two adjacent edges, so one more sample...
https://hosting.photobucket.com/imag...y/IMG_7241.JPG
https://hosting.photobucket.com/imag...y/IMG_7257.JPG
https://hosting.photobucket.com/imag...y/IMG_7258.JPG
video action:
https://www.youtube.com/watch?v=oxhk_O1FJTM
That'll do pig, that'll do.
Some of the upholstery parts have been trickling in... so let's add some bling factor....
https://hosting.photobucket.com/imag...MG_7245(1).JPG
https://hosting.photobucket.com/imag...y/IMG_7250.JPG
https://hosting.photobucket.com/imag...y/IMG_7253.JPG
https://hosting.photobucket.com/imag...y/IMG_7256.JPG
https://hosting.photobucket.com/imag...MG_7243(2).JPG
https://hosting.photobucket.com/imag...MG_7244(2).JPG
….and we made a hand punch for setting the trim tag rivets on the cowl...
https://hosting.photobucket.com/imag...y/IMG_7192.JPG
https://hosting.photobucket.com/imag...y/IMG_7193.JPG
video version:
https://www.youtube.com/watch?v=gUl3K5uN5h0
And finally, we also had some 3/8 stainless fuel line to straighten out of it's coil for a big block mopar… Video parts 1, 2, and 3:
https://www.youtube.com/watch?v=H7eDRdQ-hco
https://www.youtube.com/watch?v=np4Lae3FTC8
https://www.youtube.com/watch?v=8NsOkSsVxZ8
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More progress in the shop, another upholstered piece getting assembled... this one the driver's side rear kick panel. Our polished stainless seat belt escutcheons are installed, one in the front for the lap belt and up top for the shoulder belt.
https://hosting.photobucket.com/imag...MG_7286(1).JPG
https://hosting.photobucket.com/imag...MG_7284(1).JPG
Midrange and tweeter installed....
https://hosting.photobucket.com/imag...MG_7287(1).JPG
https://www.youtube.com/watch?v=k5egWQaN1MY
And we got a new "radius" fixture for the Tommasini wheeling machine, allows you to use it to form radius on flat bar and other shapes..
https://hosting.photobucket.com/imag...MG_7281(1).JPG
action shot....
https://www.youtube.com/watch?v=r9e822YCYIE
very nice interior
Overdue for another update...
So with all three milk cans delivered, why not a dinner bell? Indeed. This one was missing the clapper, so that's the latest fabrication...
https://hosting.photobucket.com/imag...y/IMG_7371.JPG
A used 2" hitch ball was reworked in the lathe, and looks like this will be a good start...
https://hosting.photobucket.com/imag...y/IMG_7366.JPG
Hammer/bench head stand is used as a welding fixture.. Hey, whatever works..
https://hosting.photobucket.com/imag...y/IMG_7367.JPG
root pass
https://hosting.photobucket.com/imag...y/IMG_7368.JPG
https://hosting.photobucket.com/imag...y/IMG_7369.JPG
https://hosting.photobucket.com/imag...y/IMG_7372.JPG
https://hosting.photobucket.com/imag...y/IMG_7374.JPG
Finished product in action:
https://www.youtube.com/watch?v=F875Q5qoVqY
We had some dings in the F7 hood to remove that were located in the radius along the sides.. Didn't really have a hammer that fit the exact requirement, so I use a "KIT" that my buddy Will Cronkrite had given me, a piece cut out of a Model A leaf spring.
I had more than one BF603 in stock, and rarely use the pick end, so it became the likely candidate.
https://hosting.photobucket.com/imag...y/IMG_7334.JPG
https://hosting.photobucket.com/imag...y/IMG_7335.JPG
https://hosting.photobucket.com/imag...y/IMG_7336.JPG
TIG welded in place using ER312 rod
https://hosting.photobucket.com/imag...y/IMG_7340.JPG
Some crown added long ways and polished up...
https://hosting.photobucket.com/imag...y/IMG_7345.JPG
https://hosting.photobucket.com/imag...y/IMG_7346.JPG
Both of the Wagon's rear kick panels are now prepped, ready to go..
https://hosting.photobucket.com/imag...MG_7289(1).JPG
https://hosting.photobucket.com/imag...y/IMG_7330.JPG
Vince has the core support and associated parts blocked and ready for some green...
https://hosting.photobucket.com/imag...y/IMG_7378.JPG
https://hosting.photobucket.com/imag...y/IMG_7379.JPG
….and speaking of paint, we got some "new" used light fixtures for the paint booth so we can see a bit better...
https://hosting.photobucket.com/imag...y/IMG_7362.JPG
Old next to new...
https://hosting.photobucket.com/imag...y/IMG_7347.JPG
Now that we can see a bit better, it's clear that the walls need a fresh coat of white...
https://hosting.photobucket.com/imag...y/IMG_7380.JPG
….And some blocking tips on the F7 hood. We have a nice crease on the inside of the hood from front to back. These scratches show that we would be taking material off the adjacent side if no other steps were taken to stop our sanding block at the center of the crease...
https://hosting.photobucket.com/imag...y/IMG_7382.JPG
By adding a strip of tape along the center, it gives us a positive stop for the sanding block..
https://hosting.photobucket.com/imag...y/IMG_7381.JPG
Then switching for the other side....
https://hosting.photobucket.com/imag...y/IMG_7383.JPG
Which leaves us a nice crease in the middle, and panels nice and flat to either side...
https://hosting.photobucket.com/imag...y/IMG_7385.JPG
I'd say you're ready to tackle the crack in the Liberty Bell.:D:LOL::LOL::LOL::LOL::LOL:
Some equipment changes in the shop.. The Baileigh MH19 was sold last week and Saturday morning was picked up for its journey to Pittsburgh...
https://hosting.photobucket.com/imag...y/IMG_7408.JPG
After the Baileigh left, we had another louver job with Cody, this time on a C10 Chevy hood. With the Lennox sitting in the corner like this...
https://hosting.photobucket.com/albu...s/IMG_4369.jpg
….. there has been a couple of occasions that large panels would run into interference with the shear. Saturday would be no exception. We had to cut the anchors with a Sawzall and slide it toward the paint booth to make room for the hood...
https://hosting.photobucket.com/imag...y/IMG_7428.JPG
https://hosting.photobucket.com/imag...y/IMG_7426.JPG
Since the Baileigh was picked up early that morning, the spot it used to be in seemed a better location to eliminate future issues with obstructions to the side.. So we used the 6000 lb capacity engine hoist to move the approx. 4000 lbs of Lennox..
https://hosting.photobucket.com/imag...y/IMG_7433.JPG
Which left this spot open for the new Powell Hammer, the replacement for the Baileigh. The dies are located higher on the new machine, so any larger panels should clear over top...
https://hosting.photobucket.com/imag...y/IMG_7436.JPG
Monday was moving day for the Powell hammer, Mario helped with the loading, unloading, and positioning exactly where it was supposed to go...
https://hosting.photobucket.com/imag...y/IMG_7438.JPG
https://hosting.photobucket.com/imag...y/IMG_7439.JPG
https://hosting.photobucket.com/imag...y/IMG_7440.JPG
https://hosting.photobucket.com/imag...y/IMG_7443.JPG
https://hosting.photobucket.com/imag...y/IMG_7444.JPG
https://hosting.photobucket.com/imag...y/IMG_7446.JPG
All that's left to do is drill some holes into the concrete and add some "peg" bolts to keep things from moving around.
Nothing like having the right tools for the job.
That's one BIG hammer! I like the innovation with the forklift, too. Looks like Mario may need a step stool if he uses that beast!
What Charlie said; having the right tools gets the job done right.
I think you need a bigger shed.
I've got one over here I'll sell you.
(Although the commute to work each day might take a wee bit more time than you're used to.)
Oh yeah, wagon got some paint today! Richard and Brandon Glymph of Absolute Rod and Custom Paint in Annapolis got some of the Organic green Kandy basecoat and clear sprayed.
sealer:
https://hosting.photobucket.com/imag...onPaint008.jpg
Green:
https://hosting.photobucket.com/imag...onPaint011.jpg
https://hosting.photobucket.com/imag...onPaint014.jpg
SPI Universal Clear:
https://hosting.photobucket.com/imag...onPaint016.jpg
https://hosting.photobucket.com/imag...onPaint018.jpg
Video shows some of the pop you'll see in the sunlight..
https://www.youtube.com/watch?v=zfd_Dw9uyyA
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That is AWESOME!!
This morning, out of the booth. Still waiting on some sunlight, but a shot of the two colors together...
https://www.youtube.com/watch?v=IgnwfZ5Irvw
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Wow, nice application, super shiney!
That looks laser straight and smooth as glass!!!!
I had to go back and look at some of your June on posts. Very awesome new hardware you have there! Your made tools always look so nice! Do you think a guy could use an arbor press and make flanging dies etc to work some sheet metal? That wagon is going to be a serious stunner! SEMA 2021???