Re: 55 Wagon Progress
 

That really looks great Robert..!!

Re: 55 Wagon Progress
 

Just a super nice job...Jim

Re: 55 Wagon Progress
 

That's just outstanding! When you look back through the thread there's an enormous amount of work that went into this car and every bit of it is top-notch, superb, no shortcuts work. Pretty damn impressive!

Re: 55 Wagon Progress
 

I know sum one that built an in closed trailer because he was afraid of being recked by rubber necks love the paint

Re: 55 Wagon Progress
 

Thanks for all the feedback guys!! Yeah, Brandon and the guys did a bang up job on the paint.. Will be turning some heads when Dana takes it out.


We stopped by the upholstery shop on Friday, they had the console ready...


https://hosting.photobucket.com/imag...y/IMG_7801.JPG


Video:


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


Playing catch-up here on the F7 hood, the inside of the crease was blocked using tape to keep the center line sharp, then brace welded in place and some epoxy touch ups done..

https://hosting.photobucket.com/imag...y/IMG_7450.JPG


https://hosting.photobucket.com/imag...y/IMG_7469.JPG


https://hosting.photobucket.com/imag...y/IMG_7472.JPG


With the touch ups blocked, we're ready for some Epoxy/sealer, some PPG ESSS base, and my first time spraying SPI Universal... WooHoo! love this clear!!


https://hosting.photobucket.com/imag...y/IMG_7844.JPG


These Ford truck hoods can be a pain to get good paint coverage inside the nose.. So a couple pieces of TIG wire from our rack to the hood brackets hold it up in the air so we can get into the nose with the spray gun..


https://hosting.photobucket.com/imag...y/IMG_7846.JPG


https://hosting.photobucket.com/imag...y/IMG_7849.JPG

Re: 55 Wagon Progress
 

Nice!

Re: 55 Wagon Progress
 

looks great Robert....no suprise there...

Re: 55 Wagon Progress
 

Here's a video we did on some basic metalshaping, making a heat/AC vent bracket for under the dash using a hammer and piece of pipe. Excuse the audio quality at the start, what you get for filming with an iPhone 6S. S stands for SUCKS... apparently the phone gets confused as to which of 3 microphones to use.


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













.

Re: 55 Wagon Progress
 

Nice progress....

Re: 55 Wagon Progress
 

Nice show and tell on that Robert...

Re: 55 Wagon Progress
 

Thanks for the comments guys.. Greg, EXCELLENT question!!!!


When you place a weld on a corner, and for an example, lets say we are patching a lower fender right up to the door opening to repair some rust at the bottom of the fender.... you lose the ability to control the two perpendicular sides. Let's say you blow a hole and have to re-weld in a spot or two. More heat and shrinking is bound to pull at the panel, and now you are pulling inward in two directions. The weld seam directly in the corner makes it difficult at best to planish and control where the metal gets stretched to, IF you can even make headway on it. So you'll find that in addition to having low spots, you also have altered the door to fender GAP with little hope of fixing it without filler.. By shaping your panel as you want it, and then tipping a flange that carries the seam into the perpendicular side, the crease helps to hold things from moving. Place the weld seam far enough away from the corner that you can hammer and dolly. With the brackets we made Saturday, this was easy as we just used the pipe once again, this time to planish the TIG weld once completed.

Re: 55 Wagon Progress
 

Thanks for the explanation Robert..(now that I've watched it 4 times...I see now...)..you caught me before I edited it..
What you described was the very issue I had on some of the stuff I've done by trying to weld corners together..

Re: 55 Wagon Progress
 

Greg, first off, you've had some good questions that others are likely thinking but not asking, so please stop editing!! :lol:


Next, Robert doesn't overlap. These got butt welded and dressed, as shown in the still photo at the end. The last part of the video showing the parts together is actually butted and has a couple magnets inside holding the parts together, so that may be why it looked overlapped. ;)

Re: 55 Wagon Progress
 

Haha..I'll quit editing...you caught me again though..
At the start it looked overlapped and at the end it looked butt welded

Re: 55 Wagon Progress
 

Greg, I showed some of the welding pics in here for you! :lol:




Well I think we're long overdue for a wagon update. Yes, it is back in the building....


https://hosting.photobucket.com/imag...y/IMG_7898.JPG


And we should be setting the body back on the chassis this weekend. We've been buttoning up some last minute things on the frame before a body makes accessibility more of a challenge. The cable for the O2 sensor up to the EFI was about two feet too long, so we ordered another connector and shortened it up a bit.


https://hosting.photobucket.com/imag...y/IMG_7900.JPG


In order to better hold things from bouncing around, a large Adel clamp is "massaged" to better fit the shape of the Bosch connector, and yet remain loose enough to remove the connector if need be for any future troubleshooting needs..


https://www.youtube.com/watch?v=hJT8_trcz2Q


https://hosting.photobucket.com/imag...y/IMG_7996.JPG


https://hosting.photobucket.com/imag...y/IMG_7998.JPG


https://hosting.photobucket.com/imag...y/IMG_7999.JPG


….and here's our leftover.


https://hosting.photobucket.com/imag...y/IMG_8007.JPG


Next, we had transmission cooling lines to run, which means straightening a coil of stainless 5/16 line....


https://hosting.photobucket.com/imag...y/IMG_7928.JPG


This should be straight enough....


https://hosting.photobucket.com/imag...y/IMG_7929.JPG


We had to insure clearance around the inspection cover and starter, so those were temporarily installed...


https://hosting.photobucket.com/imag...y/IMG_7935.JPG


We found these fancy stainless "cable ties" at McMaster, but even using a banding tool to tension it, the "tang" retention allows it to loosen slightly before the tang locks in.


https://hosting.photobucket.com/imag...y/IMG_8011.JPG


https://hosting.photobucket.com/imag...y/IMG_8009.JPG


https://hosting.photobucket.com/imag...y/IMG_8008.JPG


Since I had recently picked up a pair of Pex crimpers at a pawn shop for cheap, we thought we'd give those Oetiker clamps a shot for keeping things snug.. Looks like this may work!


https://hosting.photobucket.com/imag...y/IMG_8097.JPG


Top side...


https://hosting.photobucket.com/imag...y/IMG_8098.JPG


Bottom...


https://hosting.photobucket.com/imag...y/IMG_8099.JPG


The crimpers/pliers we used... $15 at a pawn shop...


https://hosting.photobucket.com/imag...y/IMG_8102.JPG


Running the radiator ends...


https://hosting.photobucket.com/imag...y/IMG_8104.JPG


https://hosting.photobucket.com/imag...y/IMG_8135.JPG


And then some other superfluous stuff, we got the second vent bracket welded up last night


https://hosting.photobucket.com/imag...y/IMG_8143.JPG


https://hosting.photobucket.com/imag...y/IMG_8144.JPG


https://hosting.photobucket.com/imag...y/IMG_8145.JPG


And even though it's off in the near distance, it's about time to repaint the tag so DMV can register it to the car (1955 only had one plate in MD)...

Thought I had some bus paint that was close, but looks a bit too light..


https://hosting.photobucket.com/imag...y/IMG_8133.JPG


But playing with some mixing ratios online, I may be able to use some of my one shot lettering paint as a tint to get us much closer...


https://hosting.photobucket.com/imag...y/IMG_8134.JPG


And since the rest of the bits are now being cut and buffed, we better get the body on the frame to make some room in the shop..


https://hosting.photobucket.com/imag...y/IMG_8147.JPG


https://hosting.photobucket.com/imag...y/IMG_8149.JPG


https://hosting.photobucket.com/imag...y/IMG_8150.JPG


….and between all that, we made another set of window dividers, these going to Dallas for the restoration of a 57 wagon...


https://hosting.photobucket.com/imag...y/IMG_8073.JPG

Re: 55 Wagon Progress
 

Robert, very cool update, and everything is looking super, nice work...Jim

Re: 55 Wagon Progress
 

more good work Robert....and look at those (butt welds)...nicely done ...haha

Re: 55 Wagon Progress
 

Thanks for following along guys!



Last night we got some details crossed off the list, our radiator sits on the front side of the core support but the overflow can't stay on the front side as it would spew all over a painted splash pan. So we marked the core support baffle to align with our overflow AN fitting and as Jared was drilling the hole and installing the grommet, I got to bending some 1/4" stainless tubing. Now it will drain behind the frame rail...



https://hosting.photobucket.com/imag...y/IMG_8159.JPG



https://hosting.photobucket.com/imag...y/IMG_8160.JPG



https://hosting.photobucket.com/imag...y/IMG_8161.JPG



https://hosting.photobucket.com/imag...y/IMG_8163.JPG



https://hosting.photobucket.com/imag...y/IMG_8164.JPG



https://hosting.photobucket.com/imag...y/IMG_8162.JPG



Since McMaster had made a delivery we got some of the Oetiker clamps installed. Yeah, I think I like this cleaner look...



https://hosting.photobucket.com/imag...y/IMG_8165.JPG



https://hosting.photobucket.com/imag...y/IMG_8166.JPG



My buddy Jeff Ford down in Aiken SC was working on installing a floor pan patch and had omitted the flange in the radius corner below the toe panel.



https://hosting.photobucket.com/imag...y/IMG_8157.JPG



So in addition to busting his chops, we put together this video tutorial so he could do the next panel in one piece. Hope it helps someone else as well..



https://www.youtube.com/watch?v=V-R_kVKKBEI





.

Re: 55 Wagon Progress
 

Very clean...oetiker clamps are a nice clean touch...

Re: 55 Wagon Progress
 

Robert,I like the looks of the Oetiker clamps, but I'm not familiar with them. Are they reusable and how do they unfasten?

Rick

Re: 55 Wagon Progress
 

One time use and they have to be cut off. Harley Davidson uses these on their fuel lines and I believe oil lines.

Re: 55 Wagon Progress
 

Well today was slated as lift-off day. So we got our lifting eyes installed on the body this morning and set up the lifting devices.

https://hosting.photobucket.com/imag...y/IMG_8177.JPG

We loaded the frame onto the trailer, figured a winch would be easier than pushing..

https://hosting.photobucket.com/imag...y/IMG_8179.JPG

Getting the body ready to separate from the rotisserie...

https://hosting.photobucket.com/imag...y/IMG_8182.JPG

https://hosting.photobucket.com/imag...y/IMG_8183.JPG

https://hosting.photobucket.com/imag...y/IMG_8185.JPG

https://hosting.photobucket.com/imag...y/IMG_8186.JPG

https://hosting.photobucket.com/imag...y/IMG_8187.JPG

https://hosting.photobucket.com/imag...y/IMG_8188.JPG

https://hosting.photobucket.com/imag...y/IMG_8191.JPG

With the body bolted down, we moved it outside to take some pictures..

https://hosting.photobucket.com/imag...y/IMG_8198.JPG

https://hosting.photobucket.com/imag...y/IMG_8200.JPG

Here is the room we have behind the engine for access to the O2 sensor connector...

https://hosting.photobucket.com/imag...y/IMG_8204.JPG

https://hosting.photobucket.com/imag...y/IMG_8205.JPG

Our attempt to install the rear bumper so we could look at it with some chrome on the rear end did not fare well. The bumper brackets did not line up correctly, just my luck, so we added length and welded the original holes closed so they can be moved to the correct location...

https://hosting.photobucket.com/imag...y/IMG_8206.JPG

Re: 55 Wagon Progress
 

Robert, coming together and looks stunning...Jim

Re: 55 Wagon Progress
 

WOW..!!!!...that green is gorgeous ..!!!..but im a sucker for green,,my 1st truck was green...

Re: 55 Wagon Progress
 

Thanks Robert, I guess my only concern would be if you had a problem out on the road. With everything being new it shouldn't be an issue anytime soon.

Rick

Re: 55 Wagon Progress
 

Rick, we'll have to include spares for the glove box...

Re: 55 Wagon Progress
 

So this weekend we played with blocks. Made from 2x6's, and gave the wagon a lift kit. This should help in using a creeper for any underside work..



https://hosting.photobucket.com/imag...y/IMG_8220.JPG



https://hosting.photobucket.com/imag...y/IMG_8221.JPG



Mike wanted to get started on the wiring harness, but we thought it best to install the brake bracket assy first. As luck would have it, the plastic bushings did not fare well with the install. We took the opportunity to make bushings out of oilite bronze, something more fitting in a 55 Chevy over plastic.



https://hosting.photobucket.com/imag...y/IMG_8226.JPG




https://hosting.photobucket.com/imag...y/IMG_8223.JPG



https://hosting.photobucket.com/imag...y/IMG_8224.JPG



https://hosting.photobucket.com/imag...y/IMG_8222.JPG



https://hosting.photobucket.com/imag...y/IMG_8225.JPG



https://www.youtube.com/watch?v=4Ibn...ature=youtu.be



.

Re: 55 Wagon Progress
 

With the brake pedal sporting new oilite bronze bushings, Mike got all the pedal assemblies installed, and hole drilled in the floor for the parking brake cable.. Then on to underneath stuff, installing the flex plate bolts and torqueing them down. We used the starter to bump the engine around, and found we also needed to shim the starter, so that was done.



https://hosting.photobucket.com/imag...y/IMG_8270.JPG



The AC vent brackets were folded using the magnetic brake....



https://hosting.photobucket.com/imag...y/IMG_8265.JPG



https://hosting.photobucket.com/imag...y/IMG_8267.JPG



Then trim the ends and one more media blast session to get it ready for epoxy primer.



Jared and I worked on getting all the body mounts snugged down, and then turned attention to the rear bumper. In the stock configuration this is slightly wide, so we had opted for a slice and dice and making the three piece bumper into a one piece..



https://hosting.photobucket.com/imag...y/IMG_8244.JPG



https://hosting.photobucket.com/imag...y/IMG_8247.JPG



https://hosting.photobucket.com/imag...y/IMG_8261.JPG



We had intended to get this done prior to paint, just one of those things that slipped through the cracks before it got sent out for paintwork. We did have some rags used between the bumper and body to prevent any damage, and removed them for pictures. The final fitment after tacking:



https://www.youtube.com/watch?v=CiSJfE7_i4E



Our data plate for the firewall had been looking pretty sad....



https://hosting.photobucket.com/imag...y/IMG_8128.JPG



…...so much so that we had thought about leaving it off the nice shiny firewall..



https://hosting.photobucket.com/imag...y/IMG_8218.JPG



But we had sent some pictures of the carnage to Bob at Alternative Chrome in Kutztown PA, and he said he could clean it right up and add a sealer for us.. Much better...



https://hosting.photobucket.com/imag...y/IMG_8231.JPG

Re: 55 Wagon Progress
 

Starting some of our electrical work, since the fuel pump and float assembly both connected using ring terminals, we wanted to use some weather pack connectors so there would be a quick disconnect. We had purchased one of the weather pack "kits" from Jegs in order to have a selection to work from as we put the car back together..



https://hosting.photobucket.com/imag...y/IMG_8286.JPG



On our standard terminal lugs, we pulled insulating sleeve off the back side so we could use a "W" crimp, and then covered with heat shrink.



https://hosting.photobucket.com/imag...y/IMG_8307.JPG



Some anti seize was applied to the connection to help keep corrosion controlled, and some braid loom and heat shrink was used to add some protection.



https://hosting.photobucket.com/imag...y/IMG_8312.JPG



https://hosting.photobucket.com/imag...y/IMG_8313.JPG



Weather pack connection, wires stripped just enough for the W crimp, strain relief crimp remains on top of the wire's jacket insulation.



https://hosting.photobucket.com/imag...y/IMG_8308.jpg



https://hosting.photobucket.com/imag...y/IMG_8309.JPG



https://hosting.photobucket.com/imag...y/IMG_8314.JPG



Next, to finalize our parking brake situation, we needed to drill a hole in the floor, which then had epoxy primer applied to the perimeter. Once cured, we installed a rubber grommet and fed through the floor. If you recall, the Lokar cable did not fit the opening in our donor brake pedal assembly, so a thick washer with the correct smaller hole was found, and the bracket hole was opened up to the outer diameter of the washer...



https://hosting.photobucket.com/imag...y/IMG_6912.JPG



Then the washer was TIG welded in place..



https://hosting.photobucket.com/imag...y/IMG_6915.JPG



https://hosting.photobucket.com/imag...y/IMG_6916.JPG



Next challenge, the brake assembly had an internal pedal return spring that would now rest on the cable and rub in the same place on the ends, so in order to minimize any wear through the cable strands, the spring was relocated to the side of the frame at the adjusters where a shoulder was machined into the adjustment fittings to support the spring ends and not rub into the cable.



https://hosting.photobucket.com/imag...y/IMG_6997.JPG



To further protect the cable from spring rub, as there surely would be deflection of the spring as the brake was applied, we test fit some heat shrink to act as a protective sleeve. The internal liner of the Lokar cable was roomy enough for the heat shrink to pass up inside, so concept test complete, we ordered some high heat Teflon shrink tubing from McMaster. This was installed over the cable, with plenty of extra slid up in the liner, and assembled all the parts..



https://hosting.photobucket.com/imag...y/IMG_6998.JPG



https://hosting.photobucket.com/imag...y/IMG_8293.JPG



https://hosting.photobucket.com/imag...y/IMG_8294.JPG



https://hosting.photobucket.com/imag...y/IMG_8295.JPG



https://hosting.photobucket.com/imag...y/IMG_8297.JPG



https://hosting.photobucket.com/imag...y/IMG_8299.JPG



That should hold us.....

Re: 55 Wagon Progress
 

Fantastic work! That thing is a stunner. Cannot say how much I love that green.

Re: 55 Wagon Progress
 

Thanks!!



Oh yeah! Made a trip to Annapolis Wednesday, Brandon and Richard were done buffing parts... Hell of a way to transport fenders and doors....



https://hosting.photobucket.com/imag...y/IMG_8317.JPG



https://hosting.photobucket.com/imag...y/IMG_8315.JPG



https://hosting.photobucket.com/imag...y/IMG_8320.JPG



https://hosting.photobucket.com/imag...y/IMG_8321.JPG



https://hosting.photobucket.com/imag...y/IMG_8322.JPG

Re: 55 Wagon Progress
 

Beautiful work and paint...Jim

Re: 55 Wagon Progress
 

that looks so nice...id been a nervous wreck hauling that stuff home..

Re: 55 Wagon Progress
 

Thanks guys! Greg, I was a bit more slow lane than my norm.. ;)



Back when we were shaving all the holes in the firewall, the dimmer switch in the floor actually went THROUGH the floor where the connections were made on the outside, and only the push actuator stuck through the floor. Not wanting anymore electrical connections outside the floor than needed, we welded up the center hole, and kept the floor nuts to bolt the new one inside.. Any never gave it any more thought. Until this weekend. Our dimmer switch, a DS115 has a bolt pattern of about 1.75" between hole centers. The factory nuts are about 2.625" between hole centers. Oh well, back up and punt has become second nature with this project..



https://hosting.photobucket.com/imag...y/IMG_8330.JPG



https://hosting.photobucket.com/imag...y/IMG_8331.JPG



So we started by fabricating an "adapter bracket" using 16 gauge stainless and a 1/4-20 press stud.



https://hosting.photobucket.com/imag...y/IMG_8333.JPG



https://hosting.photobucket.com/imag...y/IMG_8334.JPG



Next, the left bolt needed to be 1/4-20 to fit in the hole of our dimmer switch and with the floor hole at 5/16-18, we need another adapter. So two set screws of appropriate size were welded together, and this allows using an allen wrench to install and hold while tightening the nuts to hold down the dimmer switch.



https://hosting.photobucket.com/imag...y/IMG_8332.JPG



The right screw remains 5/16-18 through, but we are going to find something with a smaller (shorter) profile for under the carpet.



https://hosting.photobucket.com/imag...y/IMG_8335.JPG



https://hosting.photobucket.com/imag...y/IMG_8336.JPG



…..with plenty of room for the wiring inside



https://hosting.photobucket.com/imag...y/IMG_8339.JPG



Mike and Jarod got the fuel tank along with fill and vent tubes installed...



https://hosting.photobucket.com/imag...y/IMG_8363.JPG



https://hosting.photobucket.com/imag...y/IMG_8360.JPG



https://hosting.photobucket.com/imag...y/IMG_8369.JPG



https://hosting.photobucket.com/imag...y/IMG_8370.JPG



…..and then finished our "flexible" lines from the hard lines on the frame up to the EFI.



https://hosting.photobucket.com/imag...y/IMG_8371.JPG



https://hosting.photobucket.com/imag...y/IMG_8372.JPG



https://hosting.photobucket.com/imag...y/IMG_8374.JPG



We still have clamps to install.. Up at the EFI, 30* fittings were used to give us a downward trajectory but yet high enough to keep off the heat of the intake (that the 45* would have done).



https://hosting.photobucket.com/imag...y/IMG_8376.JPG



https://hosting.photobucket.com/imag...y/IMG_8377.JPG



https://hosting.photobucket.com/imag...y/IMG_8378.JPG

Re: 55 Wagon Progress
 

Robert, great work, as usual, looking super...Jim

Re: 55 Wagon Progress
 

Thanks Jim!!



A while back I picked up some used body tools, including this bumper puller/straightener (red handle). The rubber pad was about falling off, with exposed rivets, but since I was just hanging it up as wall art, didn't think much past that..



https://hosting.photobucket.com/imag...y/IMG_8349.JPG



Fast forward to last weekend, and a square body 4WD stopped by, which has the typical bumper ears not parallel to the ground. So I pulled the tool out to show the owner that there was indeed a way to repair that. And then decided we need to go ahead and repair the tool so it could be put back in service for when the next time the truck stopped by...


First order of business was to remove the old fender bolt and nut and replace with a machine bolt and lock nut.



https://hosting.photobucket.com/imag...y/IMG_8350.JPG



https://hosting.photobucket.com/imag...y/IMG_8351.JPG



Next, for our "replacement" pad, we had a small piece of horse mat we could cut it out of, and one of our counterbore bits was used to get the screw heads below the surface..



https://hosting.photobucket.com/imag...y/IMG_8352.JPG



https://hosting.photobucket.com/imag...y/IMG_8353.JPG




The pad was held in place using 10-32 pan head screws and lock nuts.




https://hosting.photobucket.com/imag...y/IMG_8356.JPG




This tool works by placing the pad against the bumper face, hooking the top or bottom back edge (depending on direction of pull needed) and prying to twist back into shape.. So now our wall art is all ready for next time...

Re: 55 Wagon Progress
 

Robert, it has been ages seen I've seen one of these, nice repair too...Jim

Re: 55 Wagon Progress
 

Wow that's amazing!!

Re: 55 Wagon Progress
 

Thanks guys!!


Some weekend progress... Fine tuning the rear bumper fitment.



https://hosting.photobucket.com/imag...y/IMG_8398.JPG



Driver's side fits well to the profile of the rear of the quarter...



https://hosting.photobucket.com/imag...y/IMG_8396.JPG



Passenger side not so much, so the bumper is marked with some fineline tape for where we will sand down the edge to better match..



https://hosting.photobucket.com/imag...y/IMG_8390.JPG



Leading edge of drivers side needs some trimming...



https://hosting.photobucket.com/imag...y/IMG_8393.JPG



https://hosting.photobucket.com/imag...y/IMG_8392.JPG



….as does the center section behind the tail pan..



https://hosting.photobucket.com/imag...y/IMG_8391.JPG



Next, in order to test fit the front bumper and provide the same "trim fitting" we will need to install the doors and front fenders. So our hinges got some new braid loom and a pull wire installed for the hidden wiring..



https://hosting.photobucket.com/imag...y/IMG_8406.JPG



The tapped holes in the door's nut plates were chased to insure the fresh paint did not interfere with the bolts..



https://hosting.photobucket.com/imag...y/IMG_8404.JPG



https://hosting.photobucket.com/imag...y/IMG_8407.JPG



https://hosting.photobucket.com/imag...y/IMG_8410.JPG



https://hosting.photobucket.com/imag...y/IMG_8427.JPG



https://hosting.photobucket.com/imag...y/IMG_8429.JPG



https://hosting.photobucket.com/imag...y/IMG_8430.JPG



https://hosting.photobucket.com/imag...y/IMG_8431.JPG



All buttoned up for the day, and under Kramer's watchful eye..



https://hosting.photobucket.com/imag...y/IMG_8432.JPG

Re: 55 Wagon Progress
 

Looking really nice ...Kramer looks like he approves..