Thanks guys, wait until you see all the scraps left over. As we found with some of the practice pieces, when you try to shove metal too much into a hole it tends to pull in from the edges. So to fix that we'll make up a new bottom die to form the ramp fold fully, then change back to the above die to form the step.. The down side to using phenolic is that it gives a bit where it doesn't make sharp creases well or short reverse folds either. The initial practice pieces wouldn't fold the step down flat, so a wrap of steel was added to the top die to better persuade the step flat... The upper die holder helps keep the wrapped steel in place. That did the trick, step is laying down nice and flat.. The front flange hangs over just a bit too much, some hammer action will bring it back in place. Real pleased with how well this turned out.. Some of the practice scraps..
Next task on the list is to add the semi-circular relief areas into the new cowl repair panel.. A suitable piece of Phenolic is cut out, notched at the bottom for "vise support", and used a roloc sander and drum sander to add the relief area in the "hammer form". Here's the Vise support shown in action... should remain nice and stable through all the hammer action.. Centerline of the hammerform marked, as well as on the vise, to better align our new cowl.. Door skin hammer will be used here to provide the radius, this one was touched up as the factory radius was a bit too large. Tried it on one of our scrap pieces first.. Back side.. Front side and comparison to the factory version Action video showing the process:
Thanks for the step by step process on this piece. It really does look like the factory piece, well done!
Best thread on the HAMB right now, the thought process and execution of the task at hand are amazing. Craftsmanship at its best.
Thanks for the comments guys.. A bit further along on the cowl repair.. Repair patch trimmed to size... ....and then scribed to the cowl area, which gets rough cut using the 4-1/2" cut off wheel. About 1/4" excess is left for final trimming using the snips.. That should flow some air... Tacked in place..
Thanks for the comments guys. OK, it's been a while since I've TIG welded, and got a little too much heat near the edge. Blew a nice hole, so used one of the practice pieces to cut out a patch.. .....and I got a little heavy footed on the other end as well... Trimming for the patch's patch. The final pieces to weld... Weld dressed and factory relief added... A few more welds to dress and this will be done...
Thanks for the comments guys... Cowl repair all complete... One more thin spot from the media blasting where we had removed the leaded seam... Test fitting the patch for proper contour.. TIG welded in place... Started off with some SPI epoxy on the underside... ....and then the firewall .....as well as the new glove box door skin... The entire interior was primed by standing through the window openings... Then the outside was tackled...
Are you sold on the tig welding now and will that going to be the " go to " welding for the future? The cowl piece sure came out nice! All in primer has got to feel great, been a while coming. Looks awesome in the pics!
It was a good tight fit for welding and I figured it would be much less time in cleanup with the TIG... Well the epoxy has cured for about three days, time to put the glove box back together... The adjacent areas are scuffed for some official door skin adhesive.. ....in the form of some leftover primer from this weekend.. Good thing this gets covered up... Using the door skin hammer on the leather shot bag, the ends are folded first... and then the bottom flange... All together...
I just read this whole thread.... You guys do amazing amazing work. Made me think I'm running my current project. I'm just going to have to try harder! Thank you for your inspiration.
Thanks for the comments guys. Sorry I've been lax on wagon pics. When you get to the bodywork stage it doesn't show progress well. We did get another dose of SPI epoxy sprayed on the quarters today so we can better see how we're coming along..
Well after block sanding the latest coat of epoxy.... We had a local car show we could attend, but didn't know whether to take the body or the frame... I didn't think the rotisserie would fit in my 16' trailer for some reason, but another measurement proved otherwise. Since it showed more of our metal fabrication, we opted for the body.. All loaded up, height limitations on the ceiling do require inverted travel... At the show with the "trailer queen"
On one of your videos " I don't remember where I seen it" you posted a couple of pics about tucking with modified vise grips. Do you have a video or some posts somewhere in more detail ., Thanks Love your work.
Haha, isn't that the truth OJ! Don't recall doing a video on it, but this thread(s) here shows a pretty good use of the tucking tool. If making a set, don't forget the middle "finger" ?? is set about 30 degrees from the others so the tuck is tapered.. http://www.garagejournal.com/forum/showpost.php?p=4100339&postcount=728 http://www.garagejournal.com/forum/showpost.php?p=4161992&postcount=747
Show off! Haha! I love to see cars shown in progress at events, Sometimes much more interesting than the finished ones.
Had as much of a crowd as any other car there. Even surprised to see some taking pictures and selfies in front of it! haha
The Jalopy Journal
