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Thread: 55 Wagon Progress
          
   
   

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  1. #1126
    34_40's Avatar
    34_40 is offline CHR Member Visit my Photo Gallery
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    Car Year, Make, Model: 34 Ford 3W Coupe Replica
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    One side of my family runs a small disposal company. About a dozen trash trucks.. all green and just like your samplers!

    I refuse to own any green vehicle! 8-)
    MP&C likes this.

  2. #1127
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    Quote Originally Posted by RichB View Post
    Robert:
    Great stuff as always, I love the speaker grill!

    Seeing the spray outs reminds me of the difficulty I had finding a gray color I liked that had no metallic
    in it. I wondered if you had ever left the metallic out of a chosen color to try to achieve a certain look?
    I take it this would be possible with a mixing bank? I realize it would make the color much darker, but would
    this even be a viable option?

    Rich

    Rich, we're looking at a kandy finish so we need the metallic to show the depth
    Robert

  3. #1128
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    We took a short break from the wagon as we were getting set up for a metalshaping class at the shop a couple weeks ago. Here's some highlights..


    Our guest instructor this year was Pat Brubaker of Custom Rides in Hastings Nebraska. We focused on minimal tools this year. A largely forgotten tool that is (was) seen in many shops is the arbor press. Pat has developed a die set to use in the arbor press that makes it an invaluable tool to have in your metalshaping arsenal.







    This video shows tuck shrinking, much the same as using the stump, but here using less impact for less stress added to the panel..


    https://www.youtube.com/watch?v=MUQghpUVohU


    Pete Hagan brought some 2002 BMW front fenders to practice with, one having a noticeable dent in the front..





    Here we match up one of the dies to match the crown of the rear of the fender, and try our hand at removing a dent using the arbor press.


    https://www.youtube.com/watch?v=0oI9U0YJS9E


    It did a good job of removing the majority of the damage, and more importantly, without adding any more stretch. Minimal work at this point would have this ready for paint.


    We also discussed various pattern techniques, and the benefits realized with each one. One of the class participants, Laser with a Z, had brought a 1961 Impala front valance to duplicate, as it had many rust issues.





    Some of the rust issues were filled with clay in order to get a more accurate pattern.


    Flexible shape patterns show better the amount of shape in the panel, and paper patterns were used to get an accurate read on panel material size.








    The replacement panel was made in two pieces and welded together. Laser did a nice job of welding, note the consistent width in the HAZ for minimal distortion..





    Comparison:


    40FordDeluxe likes this.
    Robert

  4. #1129
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    Jake's project for the class was a replacement for our practice fan shroud from last month.. The rear edge was unfinished, so we aimed to fix that, and also make it out of aluminum to better match the radiator.





    To finish off the rear edge, we chose to add a bead to the edge and a hemmed flange to close it off, keeping the hem flat so as not to interfere with the fan.





    The beads were added, flanges tipped to attach to the baffle panel, and the linear stretch dies in the Lennox used to stretch the correct outer radius.








    We attempted various welding methods to attach the shroud to the baffle plates. The spot welder lacked the balls to make the welds, and TIG spot welds or weld passes seemed to add more distortion to our practice pieces than the precise circle we had rolled would tolerate. So we used some stainless hardware and nylock nuts to hold the parts together..





    Here are some videos of the installed shroud..


    https://www.youtube.com/watch?v=vSQf_V4Jyi8


    https://www.youtube.com/watch?v=AZQBxsxkorQ


    Some of the tips and tricks shared at the class, here is a table "extension" for a band saw to permit cutting of crowned panels SAFELY..


    https://www.youtube.com/watch?v=qNjxTbD4VrQ


    Charlie has been to our class three years in a row, and he is a pretty sharp cookie. Like some of us and getting older, he has the unfortunate issue of arthritis in his hands, and finds difficulty in using hand snips. In much the same fashion as the Beverly shears, Charlie modified a pair of right angle Midwest shears to use a handle for easier operation..








    Action video:


    https://www.youtube.com/watch?v=MLr76hsdIxM


    Material capacity stays the same, operation just becomes a bit easier, especially for those with arthritis conditions..
    Robert

  5. #1130
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    Man, that is so awesome! Very nice work and cool adapting old tools to get it done!
    MP&C likes this.
    Ryan
    1940 Ford Deluxe Tudor 354 Hemi 46RH Electric Blue w/multi-color flames, Ford 9" Residing in multiple pieces
    1968 Corvette Coupe 5.9 Cummins Drag Car 11.43@130mph No stall leaving the line with 1250 rpm's and poor 2.2 60'
    1972 Chevy K30 Longhorn P-pumped 24v Compound Turbos 47RH Just another money pit
    Tire Sizes

  6. #1131
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    We got the wagon parts pulled out of the booth this past weekend where we had them stored during the metalshaping class.





    Getting back to tying up some loose ends.. Mike cuts out the driver side of the console..











    All ready for thinning the bend lines..





    .....while Jake and I worked on tipping the edge on the second seat bolster..





    NTFDAY, randyr, falconvan and 2 others like this.
    Robert

  7. #1132
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    Been in Florida the past couple weeks for the day job, got back in time for Saturday's shop day. Jake worked on the rear seat bolster, the top profile was traced from the one we made for the driver's side but this mark needs to be on the opposite side for us to tip the flange. Easy transfer is to use a punch on the line to transfer the mark's location through the panel and then trace..











    ....and then he used various round anvils for hammer forming the corners.








    I got started on welding in the corners of the passenger console side...














    This might work yet...


    https://www.youtube.com/watch?v=Vt8wdVuMI-I


    While Jake was tipping flanges he needed some stretch in the crowned area. Looking at the too many pieces that came out of the Erco, it's possible that Jake has too much kick. We made some new spring plates out of 1/16 stainless sheet..








    Back in business...


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    Robert

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