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Thread: '56 hit by a deer this morning...
          
   
   

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  1. #106
    astroracer's Avatar
    astroracer is offline CHR Member Visit my Photo Gallery
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    Car Year, Make, Model: '88 Astro Van-BAD AST
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    Big day today! I started welding!
    The new rocker weld flange is part of the rocker now and the door jamb repair is welded in.


    The jamb patch as welded. This is ugly but there is enough weld there to grind it down for a smooth transition.

    After some clean up with a cut off wheel.

    A little work with a sanding disc and this will be ready to prime.
    I also got the new J channel fit in and trimmed.

    I drilled the rest of the rivet holes in the side wall and finished cleaning that up. A heavy coat of rust converter and some primer and this will be ready to go together.

    I got the top of the center brace cleaned up and the whole thing buried in rust converter.

    I will have to install the floor one more time to mark the edges of the floor braces so I can drill plug welding holes.
    I will trim off the excess tunnel material tomorrow and get that and the foot well cleaned up for welding. The seat riser is ready to go so getting the tunnel and foot well ready is the last step for prep.

    This should come together pretty quickly once the new J channel is installed.
    Thanks for all of the help guys!
    Mark
    NTFDAY, 34_40 and 36 sedan like this.
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  2. #107
    cffisher's Avatar
    cffisher is offline CHR Member Visit my Photo Gallery
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    Car Year, Make, Model: 57 chevy 2 dr wagon
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    your doing great I've had to alter floor braces before on 70's pickups never had one that fit right out of the box. Hope your planning on keeping this car.
    34_40 and 36 sedan like this.
    Charlie
    Lovin' what I do and doing what I love
    Some guys can fix broken NO ONE can fix STUPID
    W8AMR
    http://fishertrains94.webs.com/
    Christian in training

  3. #108
    astroracer's Avatar
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    Car Year, Make, Model: '88 Astro Van-BAD AST
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    Thanks Charlie! The new parts have all fit extremely well! I was trying to fit that brace into the wrong spot which is why it was not going well. I got some pics and from MP&C which showed me my mistake. Thankd to Robert for the help!
    One day closer!
    The new floor channel is in.


    The old floor is trimmed, cleaned and prepped for welding.


    The new floor is "just about" ready to weld in. All of the plug welding holes are punched or drilled and I am working on getting the seat braces installed.


    I have a bit of work to do on the inner rocker but that won't take long at all, I should be welding this thing in tomorrow!
    Thanks for watching and for the help!
    Mark
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  4. #109
    astroracer's Avatar
    astroracer is offline CHR Member Visit my Photo Gallery
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    The floor is in, the rockers are in and the door still opens and closes!

    The outer rocker is welded on. It's not pretty but it will do the job with a little bit of filler. Trying to weld to the old thin fender was a real B*tch...

    The floor is so solid now it's like a new car!


    I will knock down the welds a bit tomorrow and get some primer on them. The rear fender patch and front floor brace still need to go in but these are cake now that the big piece is permanent.
    Thanks to everyone who helped with pictures and advice!
    NOW... On to the driver side...
    Mark
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  5. #110
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    Car Year, Make, Model: 34 Ford 3W Coupe Replica
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    Quote Originally Posted by astroracer View Post
    The floor is in, the rockers are in and the door still opens and closes!

    The floor is so solid now it's like a new car!
    NOW... On to the driver side...
    Mark
    Always a great indicator when the doors still operate as designed! LOL. Keep up the good work - we're not bored yet!

  6. #111
    Dave Severson is offline CHR Member/Contributor Visit my Photo Gallery
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    One thing I always keep in mind when doing that kind of intense work on an old body is that if it were easy, everyone would be doing it! Very nice work Mark, definitely going to be a really first rate ride when you get it all back together.
    Yesterday is history, tomorrow is a mystery, Live for Today!
    Carroll Shelby

    Learning must be difficult for those who already know it all!!!!

  7. #112
    astroracer's Avatar
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    It isn't easy but it's nothing that can't be done with some home brewed tools and a little bit of ingenuity. I've actually had a good time getting this done, other then bruising a rib and getting some hot weld bb's done my glove... Thanks for the compliments Dave! This will definetly make this into a nice cruiser. Especially after the paint is done.
    Getting closer to wrapping up the passenger side. Both floor braces are in and I have the inner fender patch and some rocker "finishing" pieces fabbed up.
    Lots of work to get the braces to fit right. Snuggling up to the floor and inner rocker required two cuts on the rear brace and one on the front seat brace. Spent all day saturday getting those done and the front brace welded in. This morning I got the rear brace finished up and welded in as well.



    Rear brace work.



    This is the inner fender patch. It is two pieces right now just because I changed my mind on how I trimmed out the old tin. I am debating remaking this in one piece but I don't know what that will really gain me... Thoughts? Other then less welding? As it is this will get welded together before it goes in...

    Thanks for watching!
    Mark
    NTFDAY, 34_40 and 36 sedan like this.
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  8. #113
    cffisher's Avatar
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    Can't do much with inner fenders with out taking them out and that can turn into a BIG can of worms
    Charlie
    Lovin' what I do and doing what I love
    Some guys can fix broken NO ONE can fix STUPID
    W8AMR
    http://fishertrains94.webs.com/
    Christian in training

  9. #114
    astroracer's Avatar
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    Quote Originally Posted by cffisher View Post
    Can't do much with inner fenders with out taking them out and that can turn into a BIG can of worms
    Not taking them out Charlie... Just making that patch for the rusted out lower wheel well...
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  10. #115
    astroracer's Avatar
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    I didn't get out to the shop Monday night, running errands and getting the wife's car serviced used up my afternoon/evening but I hit it hard tonight.
    I welded the two pieces of the inner fender patch together and got all of the plug welding holes punched and drilled.
    The visible side.

    The inside.

    The drilled holes. I opened these up to 1/4" after I took the pic. I also drilled holes in the two flanges to weld from behind.

    After a bit of cleanup with a wire wheel the welding went fairly well except for two spots at the top of the patch. I quit chasing the holes as all they were doing was getting bigger.

    I may work on these tomorrow. I need to get a copper backup spoon on the inside but that takes two... I am only one. I'll probably just paint and seam seal them up...
    Once this is painted and sealed up I think it will look great!
    Thanks for watching!
    Mark
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  11. #116
    astroracer's Avatar
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    I have the passenger side complete other then smoothing down some of the welds and getting the worked areas prepped, painted and sealed up. I won't do any of that until the drivers side is in.
    I started looking at the drivers side last night to start cutting it out but I decided to do some A pillar work before I remove the floor. I think it's a good idea to get this area rebuilt 1st.

    I started cleaning it up last night looking for the spot welds. I'll get some pics tonight as I start digging into it.
    Most of the wiring channel on this side is pretty good and the area in front of the rear wheel well is still solid so I don't think there will be as much work replacing metal as there was on the other side.

    Looking back at the passenger side... There just wasn't much left.

    Thanks for watching guys!
    If there are any suggestions or guidance concerning rebuilding the lower A pillar, I am all ears!
    Mark
    NTFDAY and 36 sedan like this.
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

  12. #117
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    Suggestions....???...?? um.... Nah. I'll keep my mouth shut!
    36 sedan likes this.

  13. #118
    53 Chevy5's Avatar
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    Looks like you're going to make it by summer?
    Seth

    God cannot give us a happiness and peace apart from Himself, because it is not there. There is no such thing. C.S.Lewis

  14. #119
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    Quote Originally Posted by 34_40 View Post
    Suggestions....???...?? um.... Nah. I'll keep my mouth shut!
    What he said!!!!

  15. #120
    astroracer's Avatar
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    Thanks guys! I understand completely.
    I dug into the A pillar repair last nite. I lucked out on the passenger side with the condition of the metal. I didn't have to cut it all up as it was pretty solid. THIS side is another story...
    I got some of the rot cleaned out, opened up the inner rocker and started trimming off what was left of the foot board. I got enough removed so I can see what really needs to be done to repair this area. The front floor brace/body mount is still "kind of" attached to the inner rocker at the front somewhere. The back flange is completely free so getting the rest of it loosened up shouldn't be to big of a deal.
    I have most of a plan in mind to get this fixed. I took pics last nite but they are on my phone and I need to run them thru my downsizer program to get them usable. I was out in the shop till nearly 8:00 last nite and didn't even fire up the computer...
    I'll get the pics loaded and mark them up like I did for the lower A pillar on the outside during the cowl rebuild.
    Thanks for following!
    Mark
    NTFDAY, cffisher and 34_40 like this.
    If money is the root of all evil... Women must be the fertilizer...
    Link to my BAD AST Build Thread:
    http://www.clubhotrod.com/suspension...van-build.html

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