As always, Good Work. Are you also replicating / replacing the tray?
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As always, Good Work. Are you also replicating / replacing the tray?
No, I have a firewall tray that will be adapted to the front location..
Very nice work!
Very nice work,Robert.. Love it..
Had a bit of time in the shop this evening, so I worked some more on the rear of the wagon... I had left the outer part of the lower repair patch's seam of the lift gate (going through the bead detail) un-welded until the flanges all got folded, so tonight I got one side of that finished up...
http://i5.photobucket.com/albums/y16...Picture712.jpg
http://i5.photobucket.com/albums/y16...Picture798.jpg
Then the welds were cleaned up and some more tweaking of the tailgate gaps....
http://i5.photobucket.com/albums/y16...Picture799.jpg
http://i5.photobucket.com/albums/y16...Picture801.jpg
http://i5.photobucket.com/albums/y16...Picture802.jpg
Much better...
Beautiful work man, simply beautiful.
X2!!! Looks saweet!
Thanks,always fun looking in on your work! I'm amazed every time!
Great looking stuff Time and patience
Yup,,as above..Truly beautiful..
Thanks for the comments guys. Got the tail gate and lift gate gaps done this evening.
http://i5.photobucket.com/albums/y16...Picture803.jpg
http://i5.photobucket.com/albums/y16...Picture804.jpg
http://i5.photobucket.com/albums/y16...Picture805.jpg
http://i5.photobucket.com/albums/y16...Picture806.jpg
http://i5.photobucket.com/albums/y16...Picture807.jpg
Now on to some quarter panel weld planishing..
That looks great! Looking really nice compared to what you started with!
Thanks!
Spent this past weekend at Gatormeet for a metal shaping workshop.
The first day started with a tuck shrinking demo, and showing the basics of the process and how the metal reacts. We also had the tuck shrinking fixture to use.
http://i5.photobucket.com/albums/y16...Picture810.jpg
http://i5.photobucket.com/albums/y16...Picture820.jpg
http://i5.photobucket.com/albums/y16...Picture889.jpg
Camaro quarter panels are being fitted with gills for installation on a Firebird. This included fit up, trimming, Tig welding, and planishing..
http://i5.photobucket.com/albums/y16...Picture830.jpg
http://i5.photobucket.com/albums/y16...Picture813.jpg
http://i5.photobucket.com/albums/y16...Picture822.jpg
http://i5.photobucket.com/albums/y16...Picture868.jpg
http://i5.photobucket.com/albums/y16...Picture876.jpg
The International farm truck had returned, so we were able to see the finished fenders from last year..
http://i5.photobucket.com/albums/y16...Picture866.jpg
http://i5.photobucket.com/albums/y16...Picture836.jpg
http://i5.photobucket.com/albums/y16...Picture837.jpg
The rear fenders need reproducing as well, so the wire edging this year used bead roller dies..
http://i5.photobucket.com/albums/y16...Picture875.jpg
We also discussed using hammer forms, and various pattern methods to determine shape..
http://i5.photobucket.com/albums/y16...Picture861.jpg
http://i5.photobucket.com/albums/y16...Picture855.jpg
http://i5.photobucket.com/albums/y16...Picture856.jpg
http://i5.photobucket.com/albums/y16...Picture859.jpg
http://i5.photobucket.com/albums/y16...Picture877.jpg
http://i5.photobucket.com/albums/y16...Picture878.jpg
http://i5.photobucket.com/albums/y16...Picture881.jpg
http://i5.photobucket.com/albums/y16...Picture888.jpg
Our new attendee this year learning some shaping...
http://i5.photobucket.com/albums/y16...Picture867.jpg
Some rear corners fabricated for a truck bed..
http://i5.photobucket.com/albums/y16...Picture884.jpg
Some practice at fusion welding using the Tig, here's the front showing some slight undercutting..
http://i5.photobucket.com/albums/y16...Picture892.jpg
The rear side shows some good weld penetration in some areas and needs more practice in others..
http://i5.photobucket.com/albums/y16...Picture891.jpg
Just to show that slight undercutting on fusion welding was not an issue in the joint's strength, the seam was clamped in the apron brake and bent to 135 degrees, with no detriment to the weld..
http://i5.photobucket.com/albums/y16...Picture895.jpg
http://i5.photobucket.com/albums/y16...Picture901.jpg
Saturday afternoon we spent some time discussing tips and tricks to help productivity and also to help open up to new methods and ideas. Here is a rotisserie style mount for a door, helping to locate it for ease of welding or other panel repairs....
http://i5.photobucket.com/albums/y16...Picture865.jpg
http://i5.photobucket.com/albums/y16...Picture872.jpg
Another project that Gator just picked up was this Camaro. The previous owner's substandard welding attempts severely warped and damaged many of the panels where most of the exterior panels will need replacing..
http://i5.photobucket.com/albums/y16...Picture840.jpg
http://i5.photobucket.com/albums/y16...Picture842.jpg
http://i5.photobucket.com/albums/y16...Picture844.jpg
http://i5.photobucket.com/albums/y16...Picture849.jpg
http://i5.photobucket.com/albums/y16...Picture850.jpg
http://i5.photobucket.com/albums/y16...Picture852.jpg
http://i5.photobucket.com/albums/y16...Picture853.jpg
Looks like a project for the next Gatormeet! All in all, an awesome weekend for sharing and learning methods and ideas..
What a cool Class! I wish we had something like that around here.
Very cool and thanks for sharing! A guy can be over loaded with cool info and good tips at that I'm sure. On your tuck shrinking tool, did it start out as 2 punches or center punches bent and welded together? Just curious. I may make one some day to try out.
As the others have said, thanks for sharing.. (seems like I'm always saying that to you! LOL)
I was thinking the tuck tool started out as a couple of allen wrenches maybe?? I'd like to see more of that - I've never seen it before! Hint Hint!:LOL::LOL:
The tuck tool wasn't mine, it was built by Capt Kirk. It started out as two craftsman punches, the spacing between is critical, as is the shape on the end. The plans to build them are on WestCoastMetalshapers, but will require signing up to the site.
Robert, thanks for that. I may have to venture over there some day. It never hurts to learn new sheet metal skills for a guy with minimal. Haha
Another item to get crossed off the list, there was a questionable spot on the drip rail above the lift gate.
http://i5.photobucket.com/albums/y16...Picture808.jpg
http://i5.photobucket.com/albums/y16...Picture810.jpg
After cutting it out, this appears to be the factory seam for joining two sections.
http://i5.photobucket.com/albums/y16...Picture812.jpg
Looking at the profile, we'll add the top hem first...
http://i5.photobucket.com/albums/y16...Picture813.jpg
http://i5.photobucket.com/albums/y16...Picture814.jpg
Then a radius die and the skateboard wheel in the bead roller was used to add the profile to the replacement...
http://i5.photobucket.com/albums/y16...Picture819.jpg
http://i5.photobucket.com/albums/y16...Picture817.jpg
The area where the hem adds another thickness is chamfered to insure good weld penetration...
http://i5.photobucket.com/albums/y16...Picture816.jpg
All welded in place and welds dressed...
http://i5.photobucket.com/albums/y16...Picture820.jpg
http://i5.photobucket.com/albums/y16...Picture821.jpg
Much better!
Nice patch!
Very nice work!
nice job on what seems an insignificant area.
really enjoying your metalwork photos-thanks
Ditto - (The message you have entered is too short. Please lengthen your message to at least 10 characters.)Quote:
nice job on what seems an insignificant area.
really enjoying your metalwork photos-thanks
As a student I am asking: On Post #219 was it possible to mig weld and file the problem area? Why cut the area out?
That would have been a viable option had I looked at it a bit closer. With any damage that even remotely suggests rust, I tend to lean more toward cut out and replace. Where this wasn't a clear cut rust issue, I had made these drip rails previously, so I felt the end result would be better once some cutting opened the area for exploratory poking around to see how structurally sound that area actually was.
A few months ago, I had bought a 60" Starrett rule.
http://i5.photobucket.com/albums/y16...Picture636.jpg
One of the first things I checked with it was the vertical weld that joined the 4 door NOS quarter on the drivers side of the 55. Previous to this the largest rule I had was a 24", which did not show the deflection as well. When the 60" rule spanned the joint, it showed a pronounced high spot at the vertical weld instead of the gradual crown that the panel should have. I'm not one to overload something with bondo to cover up something like this, so the vertical weld as well as part of the horizontal was sliced open to re-adjust the panel and get the correct contour.
After the slicing was complete, despite the panels coming together slightly, the gap was slightly wider than the first time welded. The butt weld clamps did not work all that well in keeping the panels where they needed to be, and after about the third time of the square peg falling out of the hole, I made a slight modification to better keep the peg from falling out. About one third the way down, the peg was punched on all four sides to keep from falling out.
http://i5.photobucket.com/albums/y16...Picture834.jpg
http://i5.photobucket.com/albums/y16...Picture835.jpg
Although I didn't get pictures of this part, the modified clamp worked especially well in gapping the horizontal weld joint to better fit the profile template for the crown of the panel. Basically with the peg no longer falling out, the portion of the butt weld clamp shown above was used to pull out on the panel until it filled the profile template, then the panels were tacked at that point. Move another couple inches, repeat. This got the vertical crown back where it should be. This was process was repeated for the vertical weld to correct the horizontal crown along the length of the quarter, checking across the vertical seam with the 60" rule. This picture was taken afterwards with the smaller rule so I could hold all the components and the camera, but gives an idea how the "partial clamp" was used to get the panel's crown correct.
http://i5.photobucket.com/albums/y16...Picture836.jpg
I don't typically used gaps in welding panels, was kinda forced into this to get the crown corrected, so I needed to make a copper backing tool. I had some rare earth magnets so I used one along with some flattened copper pipe. Note the magnet is ever so slightly raised to insure the copper is pulled good and snug to the panel..
http://i5.photobucket.com/albums/y16...Picture839.jpg
http://i5.photobucket.com/albums/y16...Picture837.jpg
http://i5.photobucket.com/albums/y16...Picture838.jpg
Each use will tend to leave the copper soot covered, so I used a welding brush to clean the copper between each weld.
http://i5.photobucket.com/albums/y16...Picture843.jpg
Welds all complete, just a few left to planish and dress, then some panel bumping and we should have one more thing crossed off the list..
http://i5.photobucket.com/albums/y16...Picture845.jpg
http://i5.photobucket.com/albums/y16...Picture844.jpg
Now that's Master Metalcrafting! I'd say 99/100 would have hit that panel with a skim coat of filler, sanded it smooth and shot it with Hi-Build primer.
I use to wonder what all the differences were between a $20K car and a $150K car. After years of building things I know I still lack the integrity, I would have filled and moved on. One day perhaps I will get myself to find that zone consistently. Great post! It has been like reading an advanced Auto-body text book, only with more information.
I like the magnet on the copper that's a GREAT idea. I wind up proping something on the inside or get someone to hold it Again great idea Thanks
Very nice work sir!
Thanks for the comments guys. Charlie, that was a rare earth magnet, super strong. I'm sure one made for a cabinet door at the local hardware store would work equally as well.
Back to some finish work on the driver's quarter, we do have a few low spots to address.
http://i5.photobucket.com/albums/y16...Picture847.jpg
Where the wheelwell and rearward offers quite spacious accommodation for hammer work within the quarter, the window area forward of the rear wheel does not fall in the same category. So as much as it pains me, one of the Snap On body hammers was given a top chop..
http://i5.photobucket.com/albums/y16...Picture846.jpg
Yeah, this will do the trick...
http://i5.photobucket.com/albums/y16...Picture848.jpg
http://i5.photobucket.com/albums/y16...Picture849.jpg
For a dolly on the outside, the small shot bag is used to promote small, controllable stretches.
http://i5.photobucket.com/albums/y16...Picture850.jpg
After the hammer work, placing the rule at a slight angle across the seam to use as a profile gauge, the area is much better than before.
http://i5.photobucket.com/albums/y16...Picture853.jpg
This should hold this spot until paint. For now, another item checked off the list...
http://i5.photobucket.com/albums/y16...Picture860.jpg
http://i5.photobucket.com/albums/y16...Picture859.jpg
Moving to the other side, got about half of the quarter's weld seam ground flush on the outside, more to come.
http://i5.photobucket.com/albums/y16...Picture861.jpg
Thanks for adding to your day's work all the detailed photos and posts.
More great work sir! You make it look easy!
Thank You Robert. It is appreciated!
Ya might consider having some harbor freight hammers for future specialty tools, I know cutting on that snap-on hurt you almost as much as it hurt the hammer!
Just a guess here but I think the words harbor freight are not heard in Roberts' shop.:HMMM:;):LOL:
Jack.
Nothing that I've bought... :LOL:
Everyone has a drawer where they keep there "special tools"
Yup! Got my retactable antennae magnet in there, and a wierd little snaking flashlight