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Re: 55 Wagon Progress
Thanks for the video. What grit do you like on the roloc discs?
Something I do with mine is buy 3" discs and run them on a 3" arbor, then when they don't cut so well anymore I put them on a 2" arbor and while running the die grinder hit the edge with a cutting disc perpendicular to "shave" them down to about 2". Then I use them some more and repeat the process with a 1" arbor. That way I can finally feel good about throwing them away! |
Re: 55 Wagon Progress
I was using 80 grit there. I've tried 60 and 120...... 60 seems to leave too deep of scratches, 120 seems too fine/slow at acting. 80 is a happy medium. I don't change arbors, but my 3" arbor is actually about 1/4" shy, so when the outer edge loses its bite I will cut around the perimeter up to the backing using a pair of tin snips to get a bit more life out of them.
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Re: 55 Wagon Progress
Tonights repair was to duplicate one of these mounting blocks for the lift gate's gas strut.
The good one... http://i5.photobucket.com/albums/y16...cture285-1.jpg ...not so good... http://i5.photobucket.com/albums/y16...cture286-1.jpg Used a hole saw to provide some radiused ends and the 3" cutoff wheel to cut out all the torn and ragged metal.. http://i5.photobucket.com/albums/y16...cture287-1.jpg A piece of 19ga is tacked and welded....note the original color.... http://i5.photobucket.com/albums/y16...cture289-1.jpg http://i5.photobucket.com/albums/y16...cture290-1.jpg Cut out a piece from a steel angle, drilled and tapped the three 10-24 holes. This was bolted in place using anti-seize on the screw threads to prevent galling during the weld process.. then plug weld holes drilled and welded from the outside.. http://i5.photobucket.com/albums/y16...cture292-1.jpg http://i5.photobucket.com/albums/y16...cture293-1.jpg Plug welds cleaned up, checking the threads for burrs... http://i5.photobucket.com/albums/y16...cture294-1.jpg And for next time, we have one more piece to add while the bottom is still open, the floating nut plate for the tailgate latch.... http://i5.photobucket.com/albums/y16...cture297-1.jpg http://i5.photobucket.com/albums/y16...cture296-1.jpg http://i5.photobucket.com/albums/y16...cture295-1.jpg |
Re: 55 Wagon Progress
Tonight I trimmed the lower edge of the lift gate to get the final repair part fitted up.
http://i5.photobucket.com/albums/y16...cture320-1.jpg http://i5.photobucket.com/albums/y16...cture321-1.jpg Once both ends of the lift gate were trimmed, looking at the surface profile you can see we need a bit more crown at the ends of the repair part. http://i5.photobucket.com/albums/y16...cture322-1.jpg http://i5.photobucket.com/albums/y16...cture323-1.jpg To add some crown, the lower flanges on the ends were folded flat and used the Erco to shrink the bottom flange. http://i5.photobucket.com/albums/y16...cture324-1.jpg The multiple bends toward the top were another story, a 1/4 beading die lightly pushing into a skateboard wheel, and the ends were pushed in and pulled up while exiting. Here's the results... http://i5.photobucket.com/albums/y16...cture325-1.jpg http://i5.photobucket.com/albums/y16...cture326-1.jpg http://i5.photobucket.com/albums/y16...cture327-1.jpg http://i5.photobucket.com/albums/y16...cture328-1.jpg http://i5.photobucket.com/albums/y16...cture329-1.jpg Oh yeah.....you can see the top of the welding table again! :D http://i5.photobucket.com/albums/y16...cture330-1.jpg Next task on the list will be to form/fold the ends.. |
Re: 55 Wagon Progress
Speechless as always. Incredible!
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Re: 55 Wagon Progress
Keep it coming....the attention to detail is inspiring. By the way, nice welding table. dug
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Re: 55 Wagon Progress
Yeah, I'm starting to get the table filled back up again. :lol:
Another slight detour.... I need to stop looking for this stuff....or is it looking for me? This pinch weld showed swelling between the two sheets, and a closer inspection showed some rather thick scale... http://i5.photobucket.com/albums/y16...cture331-1.jpg http://i5.photobucket.com/albums/y16...cture332-1.jpg Out with the old... http://i5.photobucket.com/albums/y16...cture333-1.jpg Test fit of the new... http://i5.photobucket.com/albums/y16...cture334-1.jpg The exposed metal was media blasted, as was the inside of the newly made patch....and some epoxy primer added... http://i5.photobucket.com/albums/y16...cture335-1.jpg http://i5.photobucket.com/albums/y16...cture336-1.jpg We'll let that dry and then get it welded in place. And just to show the makeshift clamping system for cutting, grinding, and painting in an awkward spot...... http://i5.photobucket.com/albums/y16...cture337-1.jpg http://i5.photobucket.com/albums/y16...cture338-1.jpg |
Re: 55 Wagon Progress
With the epoxy well cured, holes were drilled for plug welds....
http://i5.photobucket.com/albums/y16...cture339-1.jpg Then used the modified plug weld bit for cleaning out the adjacent panel... http://i5.photobucket.com/albums/y16...cture340-1.jpg http://i5.photobucket.com/albums/y16...cture342-1.jpg http://i5.photobucket.com/albums/y16...cture343-1.jpg Cleaned spots for the plug welds... http://i5.photobucket.com/albums/y16...cture344-1.jpg http://i5.photobucket.com/albums/y16...cture345-1.jpg http://i5.photobucket.com/albums/y16...cture346-1.jpg http://i5.photobucket.com/albums/y16...cture348-1.jpg I had some questions about how well the epoxy held up to heat from welding. The epoxy next to the weld above, where it turned brown from the heat, was allowed to cool off, then attempted to scrape the paint with my thumbnail. I thought it may scrape some off, but it held tight, not so much as a scratch. Then I got on a roll and forgot pictures, but here's the patch all welded in.... http://i5.photobucket.com/albums/y16...cture349-1.jpg Next, drilled the holes in the lower window opening.... http://i5.photobucket.com/albums/y16...cture350-1.jpg .....and got the holes placed for the nut plate and it's plug welds... http://i5.photobucket.com/albums/y16...cture351-1.jpg http://i5.photobucket.com/albums/y16...cture352-1.jpg http://i5.photobucket.com/albums/y16...cture353-1.jpg Hopefully tomorrow we can get some profile blocks cut out to fold over the ends of the outer piece... |
Re: 55 Wagon Progress
Laying out the ends for trimming.....
http://i5.photobucket.com/albums/y16...cture354-1.jpg http://i5.photobucket.com/albums/y16...cture355-1.jpg Here's the piece we'll use to cut out the profile blocks, 3/4 thick steel http://i5.photobucket.com/albums/y16...cture357-1.jpg As I am fresh out of good band saw blades, these were used.... http://i5.photobucket.com/albums/y16...cture358-1.jpg The lower piece was tapered at the bottom as the bottom of the lift gate tapers in below the bead detail.. http://i5.photobucket.com/albums/y16...cture360-1.jpg .....like so..... http://i5.photobucket.com/albums/y16...cture361-1.jpg Not perfect, but should work just the same... http://i5.photobucket.com/albums/y16...cture363-1.jpg Clamped in the vise..... http://i5.photobucket.com/albums/y16...cture365-1.jpg Then some heat is applied, and hammered the high spots.. http://i5.photobucket.com/albums/y16...cture366-1.jpg http://i5.photobucket.com/albums/y16...cture367-1.jpg http://i5.photobucket.com/albums/y16...cture368-1.jpg Fitted..... http://i5.photobucket.com/albums/y16...cture369-1.jpg http://i5.photobucket.com/albums/y16...cture370-1.jpg and the other end...... http://i5.photobucket.com/albums/y16...cture373-1.jpg http://i5.photobucket.com/albums/y16...cture374-1.jpg http://i5.photobucket.com/albums/y16...cture375-1.jpg http://i5.photobucket.com/albums/y16...cture376-1.jpg Hope to test fit everything tomorrow before all the parts get media blasted.. |
Re: 55 Wagon Progress
Nice job. You have to hate rust.
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Re: 55 Wagon Progress
It has kept me busy! :lol:
Things don't always work the way you planned. Before the ends were folded, the bottom piece could never be test fit into the opening. Now with the ends folded, it was slipped over the bottom of the lift gate and it bolted into the opening. With the upper bead detail aligned, the lower was considerably off kilter. Slightly off on the contour, I guess. http://i5.photobucket.com/albums/y16...cture379-1.jpg http://i5.photobucket.com/albums/y16...cture380-1.jpg The patch piece was marked off on both ends to bring the lower bead detail up into the car for better alignment... http://i5.photobucket.com/albums/y16...cture381-1.jpg Here's the driver's side after cutting and welding, shows a much better alignment. Good weld penetration on the inside, the seam at the end will be finished after folding onto the lift gate.. http://i5.photobucket.com/albums/y16...cture383-1.jpg http://i5.photobucket.com/albums/y16...cture384-1.jpg http://i5.photobucket.com/albums/y16...cture385-1.jpg We may be able to save this yet.. |
Re: 55 Wagon Progress
Tricky Tricky! I had to do the same to Yeller's rockers. Boppa about had a fit when I just rammed his brand new rockers into the bandsaw! "Naw, It'll be cool."
Great stuff with that die. Do you like your Henrob? |
Re: 55 Wagon Progress
Amazing metal skills. Read and learned. Learned a lot.
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Re: 55 Wagon Progress
:jdp::jdp::jdp::jdp:<-----This icon explains better then anything I could say!!
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Re: 55 Wagon Progress
Thanks for the comments guys!
Quote:
Yes, It comes with about 6 different tips, lets you dial in the flame nicely for the job at hand. I got it quite a few years ago, think it's sold as Cobra torch now... |
Re: 55 Wagon Progress
Your mettle working skill continue to impress me!
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Re: 55 Wagon Progress
Caution: A couple of OT pictures follow, proceed at your own risk! :lol:
Sorry for my short hiatus from the shop, after 226K miles my trusty 16 year old truck has been giving me fits with transmission issues. After spending about 3 weeks on and off looking for good used trucks, the year end deals and rebates made a brand new one only slightly higher in price than a three year old model. So..... Out with the old... http://i5.photobucket.com/albums/y16...Picture366.jpg In with the new.... http://i5.photobucket.com/albums/y16...Picture401.jpg And with the truck shopping headaches behind us, we can get back in the shop ... Worked on the other end of the lower patch today, to fix the mis-alignment of the beltline trim... http://i5.photobucket.com/albums/y16...cture380-1.jpg Made a relief cut.... http://i5.photobucket.com/albums/y16...cture403-1.jpg http://i5.photobucket.com/albums/y16...cture404-1.jpg Rear view shows full weld penetration.... http://i5.photobucket.com/albums/y16...cture406-1.jpg Welds were planished, then ground to just above panel surface, and next weld overlapped, and repeat. The overlapping helps to eliminate any missed welds/pin holes. http://i5.photobucket.com/albums/y16...cture408-1.jpg http://i5.photobucket.com/albums/y16...cture409-1.jpg http://i5.photobucket.com/albums/y16...cture410-1.jpg http://i5.photobucket.com/albums/y16...cture411-1.jpg http://i5.photobucket.com/albums/y16...cture412-1.jpg http://i5.photobucket.com/albums/y16...cture413-1.jpg http://i5.photobucket.com/albums/y16...cture414-1.jpg http://i5.photobucket.com/albums/y16...cture415-1.jpg http://i5.photobucket.com/albums/y16...cture416-1.jpg http://i5.photobucket.com/albums/y16...cture417-1.jpg All done and cleaned up.... http://i5.photobucket.com/albums/y16...cture418-1.jpg http://i5.photobucket.com/albums/y16...cture419-1.jpg ......for a much better fit.. http://i5.photobucket.com/albums/y16...cture420-1.jpg Then media blasted the inside in preparation for some epoxy primer... http://i5.photobucket.com/albums/y16...Picture425.jpg .....and did some adjustment of the tailgate fitment. http://i5.photobucket.com/albums/y16...Picture422.jpg http://i5.photobucket.com/albums/y16...Picture423.jpg |
Re: 55 Wagon Progress
Nice new sled! How did you do the actual move of the trim ridge? I see the relief to go up, but how did you actually do it?
I can personally attest to the weld/grind/lap method. Helps keep the heat down, as well. Great tip. |
Re: 55 Wagon Progress
After making the relief cut, the lower folded section was placed in the vise for some "finesse" to persuade it upwards a bit. A pair of vise grips held the two together for the first tack, and after that things just fell into place.
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Re: 55 Wagon Progress
Got some B I G time skills.
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Re: 55 Wagon Progress
damn, i believe im gonna have to go get my socks, they blew off on the 1st page.
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Re: 55 Wagon Progress
Every time I check in I feel "schooled".
Amazing skillz,,,, Shouldn't there be a TOTY or something along side your name? |
Re: 55 Wagon Progress
Sometimes you just need to back up and punt.
Even though I have been working on this car far too long, with travel for the day job and two other resto's having been quite an interruption..... you get to where you finally see light at the end of the tunnel, and just come to grips with something that needs to come back out.... When I originally did this roof repair, I did not have the Lennox nibbler or English wheel or many of the tools I now have, and the patch panel you see below..... http://i5.photobucket.com/albums/y16...n/HPIM5655.jpg ....was fabricated using incremental bends in an apron brake. Given the creases you see due to the fabrication method, I likely made this shorter than I should have in an attempt to limit the creases, and the result was the horizontal weld was not up high enough to be readily accessible for planishing. After making these patch panels for a second roof repair...... http://i5.photobucket.com/albums/y16...Picture129.jpg .....it was more apparent that the first attempt was not the best, and if I wasn't happy with it before, this new panel really made the old one grab my attention...each time I've walked by. http://i5.photobucket.com/albums/y16...Picture437.jpg http://i5.photobucket.com/albums/y16...Picture438.jpg http://i5.photobucket.com/albums/y16...Picture439.jpg Well a person with spare patches lying around can only take so much, so tonight I checked the fit of one of the spare patch panels.... Looking at the front, the panel needed just a bit more crown.... http://i5.photobucket.com/albums/y16...Picture441.jpg And the rear needed just a bit less.... http://i5.photobucket.com/albums/y16...Picture446.jpg So with the Go Kart slick mounted up and ready to go, a 6" then 3.75" radius lower anvil added the crown needed for the front and a 24" radius flattened out the rear for a much better fit. http://i5.photobucket.com/albums/y16...Picture443.jpg http://i5.photobucket.com/albums/y16...Picture444.jpg http://i5.photobucket.com/albums/y16...Picture447.jpg http://i5.photobucket.com/albums/y16...Picture448.jpg http://i5.photobucket.com/albums/y16...Picture450.jpg http://i5.photobucket.com/albums/y16...Picture451.jpg http://i5.photobucket.com/albums/y16...Picture452.jpg These panels are about 4" high and put the weld up above the roof boxing structure, so planishing will be more accessible to give us a better job. I'll get the patch all primed on the inside and let it cure. Then cut out the old patch and get this new one welded in.. More to come.. |
Re: 55 Wagon Progress
Watchin
Wish I could work my English wheel half as good as you. |
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