Re: 55 Wagon Progress
 

Yes, really nice work. The magnetic brake is pretty handy.

Re: 55 Wagon Progress
 

Kyle is a quick learner, I think he enjoys welding especially, but we'll see this weekend how he fares with sheet metal :D

The magnetic brake does have some limitations over an apron brake, but overall it really comes in handy for radius forming and other situations where the truss of the brake would normally get in the way..

Re: 55 Wagon Progress
 

Today Kyle needed to start some welding on the hood brace, so while he was getting set up with the welder, I started making him an anvil that he could use to planish the weld dots inside the radius voids..


Heat applied...


http://i5.photobucket.com/albums/y16...ure%202085.jpg


http://i5.photobucket.com/albums/y16...ure%202086.jpg


http://i5.photobucket.com/albums/y16...ure%202087.jpg


http://i5.photobucket.com/albums/y16...ure%202090.jpg


http://i5.photobucket.com/albums/y16...ure%202092.jpg


http://i5.photobucket.com/albums/y16...ure%202093.jpg


Kyle's first job at welding sheet metal, he's a quick learner. He did have a couple spots that didn't like the heat and blew a hole, but he did a real nice job in getting those fixed as well.


http://i5.photobucket.com/albums/y16...ure%202089.jpg


Planishing weld dots on the new "anvil"..


http://i5.photobucket.com/albums/y16...ure%202095.jpg


Full weld penetration...


http://i5.photobucket.com/albums/y16...ure%202096.jpg


http://i5.photobucket.com/albums/y16...ure%202097.jpg


While he welded away, I turned my attention to the front end. The passenger door had a bit of a tight spot to the rear edge of the fender while opening.. Using a hack saw blade as a "feeler gauge", it was tight in one area. To help out the situation, time for another tool. I have a dent puller with a small pair of vise grips permanently attached, so we just need an adapter kit...


This was some leftover square tubing scraps...


http://i5.photobucket.com/albums/y16...ure%202101.jpg


http://i5.photobucket.com/albums/y16...ure%202100.jpg


In use..


http://i5.photobucket.com/albums/y16...ure%202102.jpg


After the pulling effort, the tight gap was well over two HSB thicknesses.


http://i5.photobucket.com/albums/y16...ure%202111.jpg


Moving on to other fender fitment, the bottom edge of the fender was higher than the adjacent rocker. Any adjustment was futile as the bolt was at the bottom of the adjustment hole. Time for some die grinder action to bring the hole downward and also flatten the bottom edge of the hole so any movement forward or backward doesn't push the bolt upward..... This was done on both fenders..


http://i5.photobucket.com/albums/y16...ure%202112.jpg


http://i5.photobucket.com/albums/y16...ure%202113.jpg


http://i5.photobucket.com/albums/y16...ure%202114.jpg


Test fit shows much better alignment.. This may be why the 57 went to a square hole..


http://i5.photobucket.com/albums/y16...ure%202115.jpg


Kyle done with his welding on the center patch, just needs to be dressed with the sanding disc. We'll save that for after the other patch gets welded in place..

Front:


http://i5.photobucket.com/albums/y16...ure%202116.jpg


Rear:


http://i5.photobucket.com/albums/y16...ure%202117.jpg


And I was also busy making more dust... Can't wait for springtime and the leaf blower :metal:


http://i5.photobucket.com/albums/y16...ure%202118.jpg


http://i5.photobucket.com/albums/y16...ure%202119.jpg


http://i5.photobucket.com/albums/y16...ure%202120.jpg


http://i5.photobucket.com/albums/y16...ure%202121.jpg

Re: 55 Wagon Progress
 

Are you keeping track of how many hours you have on this project.

Re: 55 Wagon Progress
 

Yes, I got a time clock at an auction a few years back and have been keeping better track of all the projects since then. Don't have a running total right now, someone asked me about that a couple weeks ago. :lol:

Re: 55 Wagon Progress
 

Someone noticed we use some rather "vintage" ice picks as scribes for metalwork, and asked to see a closer look.. I had picked these up a few years ago at an auction as my wife looks at me with that "and why do we need those" looks... The one came shorter as shown, but to prolong the life of the picks, sharpen with a very fine file, never use a grinder ;)

The auction was in Fredericksburg VA, if anyone recognizes any of the old ice plants, be sure to chime in so we can all get a history lesson. I tried calling them but nobody answered 8 or 30.. :lol:

http://i5.photobucket.com/albums/y16...ure%202131.jpg

http://i5.photobucket.com/albums/y16...ure%202132.jpg

http://i5.photobucket.com/albums/y16...ure%202133.jpg

http://i5.photobucket.com/albums/y16...ure%202134.jpg

http://i5.photobucket.com/albums/y16...ure%202135.jpg

http://i5.photobucket.com/albums/y16...ure%202136.jpg

Re: 55 Wagon Progress
 

Thats too funny, phone 8, phone 30, thats back in the 20's era i would guess, back when every little town had a switchboard and operator to physically connect each call.

Re: 55 Wagon Progress
 

Re: 55 Wagon Progress
 

Thanks for the comments guys!


Kyle finishing up on the hood brace....


http://i5.photobucket.com/albums/y16...ure%202122.jpg


http://i5.photobucket.com/albums/y16...ure%202123.jpg


Because he had gaps to contend with, we used some copper to insure less chance of blow outs. A piece of 1/2" copper pipe was flattened and bent in the press brake to make a fitted backing for the vee bead detail..


http://i5.photobucket.com/albums/y16...ure%202124.jpg


http://i5.photobucket.com/albums/y16...ure%202137.jpg


http://i5.photobucket.com/albums/y16...ure%202142.jpg


http://i5.photobucket.com/albums/y16...ure%202145.jpg


http://i5.photobucket.com/albums/y16...ure%202146.jpg


Just a bit of work with the sander and this part should be done. Like the new look without all the gaping holes..


Meanwhile, I continued to make dust. Here's a good view of the built in "guide coat" feature of the SPI. Blocking on the top of the hood shows a low spot.....


http://i5.photobucket.com/albums/y16...ure%202140.jpg


And with just a couple scuffs from the bottom, the low shows up there as well


http://i5.photobucket.com/albums/y16...ure%202141.jpg


Just a few bumps with the hammer from the bottom into the small shot bag on top and the low is gone.


And the rest looks pretty much the same other than the piles of dust on the floor moving around.. :lol:


http://i5.photobucket.com/albums/y16...ure%202139.jpg

Re: 55 Wagon Progress
 

Kyle did a really nice job on the hood brace!

Re: 55 Wagon Progress
 

Re: 55 Wagon Progress
 

Nice work, thanks for the update...Jim

Re: 55 Wagon Progress
 

Thanks for the comments guys!



He's a quick learner.. I've been pleased with his work.



A while back we had made the brackets to make up three "reproduction" battery trays based on a 1955 Chevy factory air conditioned car.


http://i5.photobucket.com/albums/y16...Picture782.jpg


The only part that did not come with the used original pieces we had as patterns was the factory hold down with it's attached "zee" bracket that secures the battery hold down to the rear of the core support, as seen here in the factory assembly bulletin.


http://i5.photobucket.com/albums/y16...ure%201999.jpg


We recently mocked up the battery location, and made a zee bracket based on the picture and the dimensions we had in front of us.


http://i5.photobucket.com/albums/y16...ure%202148.jpg


http://i5.photobucket.com/albums/y16...ure%202147.jpg


Now to make the remaining two brackets for the other two battery trays.. A roll former die in the press brake was used to make the vertical bends.


http://i5.photobucket.com/albums/y16...ure%202149.jpg


A bit of tipping using a press brake die as an anvil, and then using the tipping tool...


http://i5.photobucket.com/albums/y16...ure%202150.jpg


http://i5.photobucket.com/albums/y16...ure%202151.jpg


The finished brackets and a comparison....


http://i5.photobucket.com/albums/y16...ure%202152.jpg


http://i5.photobucket.com/albums/y16...ure%202153.jpg


http://i5.photobucket.com/albums/y16...ure%202154.jpg


http://i5.photobucket.com/albums/y16...ure%202155.jpg

Re: 55 Wagon Progress
 

Very nice work...Jim

Re: 55 Wagon Progress
 

Thanks Jim!


Today's progress, Kyle finishing up the hood brace..


http://i5.photobucket.com/albums/y16...ure%202156.jpg


http://i5.photobucket.com/albums/y16...ure%202157.jpg


http://i5.photobucket.com/albums/y16...ure%202158.jpg


While I continue to generate dust on the floor...


http://i5.photobucket.com/albums/y16...ure%202159.jpg


Recently we installed a used core support that was quite a bit nicer than our original, but still showed some issues...


http://i5.photobucket.com/albums/y16...ure%202160.jpg


Here we see some rust...


http://i5.photobucket.com/albums/y16...ure%202161.jpg


And not quite enough clearance to the petcock..

http://i5.photobucket.com/albums/y16...ure%202163.jpg


So this will be next on the list, cutting out a new one with a bit better fitment.

Re: 55 Wagon Progress
 

Brace came out really nice, young man is doing some great work...Jim

Re: 55 Wagon Progress
 

You guys make a great team.

Re: 55 Wagon Progress
 

Thanks for the comments guys... We had an early schedule today to try and miss the weather.. As I still hadn't finished blocking the front end, rather than pull the core support just yet, Kyle will start on the rear of the wagon in wrapping up some details there. Before pulling the tailgate, there was one gap that was inconsistent, so I gave him a hand with the rework before he got welding..


http://i5.photobucket.com/albums/y16...ure%202165.jpg


http://i5.photobucket.com/albums/y16...ure%202166.jpg


First to unfold the flange a bit...


http://i5.photobucket.com/albums/y16...ure%202168.jpg


http://i5.photobucket.com/albums/y16...ure%202167.jpg


Next, some 14 gauge steel was cut out and a strengthening bend added to use for some friendly persuasion..


http://i5.photobucket.com/albums/y16...ure%202169.jpg


http://i5.photobucket.com/albums/y16...ure%202170.jpg


Refolded...


http://i5.photobucket.com/albums/y16...ure%202172.jpg


For comparison, before:


http://i5.photobucket.com/albums/y16...ure%202166.jpg


After:


http://i5.photobucket.com/albums/y16...ure%202171.jpg


Then we tweaked the twist of the tailgate for good fitment to the opening and Kyle added three plug welds down each side to lock the skin to the inner tail gate.


http://i5.photobucket.com/albums/y16...ure%202173.jpg


http://i5.photobucket.com/albums/y16...ure%202174.jpg


...Then we removed the tail gate so he could finish the plug welds for the top flange of the tail pan, I had only tacked it in place when the tailpan was installed, so this should help check off another item from the list......

Meanwhile I continued blocking out the front end..


http://i5.photobucket.com/albums/y16...ure%202176.jpg


http://i5.photobucket.com/albums/y16...ure%202177.jpg


http://i5.photobucket.com/albums/y16...ure%202178.jpg


http://i5.photobucket.com/albums/y16...ure%202179.jpg

Re: 55 Wagon Progress
 

Wow, this is going to be about the most perfect 55 wagon on the planet. Nice process on the tail gate gap...I am learning a lot following along.

Re: 55 Wagon Progress
 

Thanks!


Well Kyle skipped out on me tonight, something about a birthday and his parents taking him out to dinner.. and here he could have been welding! :lol:


So I took the opportunity to have dinner with the family, so tonight was a short night...


One of the other areas I skipped over at the rear of the wagon was when the tail pan was installed. The factory version with the pinch welded flanges has a gap in the crimp seam for the rear bumper seal:


http://i5.photobucket.com/albums/y16...ure%202182.jpg


As I got rid of all the pinch weld seams at the rear of the wagon to eliminate those rust traps, the gap at the crimp seam will be filled in. To assist in filling in the wide gap, a piece of copper flat bar is used as a backer..


http://i5.photobucket.com/albums/y16...ure%202184.jpg


http://i5.photobucket.com/albums/y16...ure%202185.jpg


Next, as the reproduction tail pan has a rounded crimp seam and the area on the original quarters is more of a square, we'll add some hammer action here. The remaining piece of the flat bar is clamped in and used as an anvil..


http://i5.photobucket.com/albums/y16...ure%202186.jpg


http://i5.photobucket.com/albums/y16...ure%202187.jpg


http://i5.photobucket.com/albums/y16...ure%202188.jpg


Continuing welding...


http://i5.photobucket.com/albums/y16...ure%202191.jpg


http://i5.photobucket.com/albums/y16...ure%202193.jpg


http://i5.photobucket.com/albums/y16...ure%202195.jpg


.....and a repeat on the driver's side...


http://i5.photobucket.com/albums/y16...ure%202198.jpg


http://i5.photobucket.com/albums/y16...ure%202201.jpg


http://i5.photobucket.com/albums/y16...ure%202202.jpg

Re: 55 Wagon Progress
 

Wow! Very amazing work! I really like the fabrication of the factory style A/C battery box. It gets that ugly battery off the firewall and will let everyone focus on the engine when the hood is open. I am helping a friend with a 55 handyman wagon and there is no trunk to hide the battery. So why not hide it in plain sight? Genius! I see that you made an extra bracket so if one comes up for sale I would be first in line.

Re: 55 Wagon Progress
 

Thanks, but I only have the one set here. All the other sets were sent to WI..

Re: 55 Wagon Progress
 

Well if you decide to build more, keep me in mind. Thanks!!

Re: 55 Wagon Progress
 

I have already started using your welding process on my project. this is just too cool! Rock on bro! :metal:

Re: 55 Wagon Progress
 

And another thing, I can see that you make most of your body tools :lol: but where do you buy them at and what brand do you prefer?