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Re: 55 Wagon Progress
So a few months back when we bought the Powell Hammer there was this tubing notcher sitting there. It was for sale as well and I knew exactly who needed it. One phone call and it was sold minutes later to my buddy Mike Phillips in Downingtown PA. I brought it to my shop to hold it until he had a chance to come pick it up..
https://hosting.photobucket.com/imag...MG_8457(1).PNG In the meantime, Mike had some equipment he was selling. I had my eye on a press brake and Cousin JB (upholster in Fairfax SC) could use his jump shear. So Saturday was the day for equipment delivery/swap, Mike and his wife Stacy made the trek to Southern Maryland to the shop and dropped off my new press brake, dropped off JB‘s new foot shear (until it can make it to SC) and picked up the tubing notcher that I’m sure will be a welcome addition at Phillips Hot Rod & Customs for the next cage install. https://hosting.photobucket.com/imag...y/IMG_8453.JPG https://hosting.photobucket.com/imag...y/IMG_8454.JPG https://hosting.photobucket.com/imag...y/IMG_8455.JPG https://hosting.photobucket.com/imag...y/IMG_8456.JPG So once we get the new press brake hooked up we will likely have one or both of these leaving... https://hosting.photobucket.com/imag...y/IMG_8447.JPG . |
Re: 55 Wagon Progress
Nice manchine swaparooni you did there Robert ..just saw the video you put up...could you futher explain the new press dies?..
https://m.youtube.com/watch?v=JQM5xUd6vpw |
Re: 55 Wagon Progress
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So the lower die in the latest video is one I got with the second 24" manual press brake.....so I've had it for awhile, but didn't use it that often. It is many times used with a radius die, and all the sorted details are in this post here..... https://www.garagejournal.com/forum/...&postcount=214 . |
Re: 55 Wagon Progress
Ahhh..ok...I see now...thanks Robert..!!
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Re: 55 Wagon Progress
More progress on the wagon, more bumper action. Part of the problem with using three pieces to form the bumper with a nice wide bumper guard to hide the overlaps, is there is less of a smooth transition from end to end. So in using those individual parts to make a single bumper, we need to trim to correct this. While on the car, painters tape is used to lay out a smooth transition from end to end.
https://hosting.photobucket.com/imag...y/IMG_8391.JPG https://hosting.photobucket.com/imag...y/IMG_8388.JPG An air body saw is used to cut off the bulk and roloc sander for cleanup afterward... https://hosting.photobucket.com/imag...y/IMG_8475.JPG https://hosting.photobucket.com/imag...y/IMG_8474.JPG Jared has been helping out with the bumpers, here making tight fitting plugs to fill in the old bolt holes for a smooth look on the outside. https://hosting.photobucket.com/imag...y/IMG_8501.JPG https://hosting.photobucket.com/imag...y/IMG_8479.JPG Our front bumper center section had a bit more damage to repair, the center section showed it had been used to pull/tow/?? in a previous life... As the car was pulled, it added some creases as the center pulled outward.. https://hosting.photobucket.com/imag...y/IMG_8440.JPG A bit of off-dolly with a rather large hammer and we're much better now. https://hosting.photobucket.com/imag...y/IMG_8442.JPG The center section also had a stepped flange on either end so the outer pieces would be flush when mounted. As we are making one-piece bumpers, the step is trimmed to length and the step is flattened using a precision flattening device.. https://hosting.photobucket.com/imag...y/IMG_8451.JPG Video version: https://www.youtube.com/watch?v=DCuKjivvr7Q Next, we wanted shaved fasteners but also still wanted some fine-tune adjustability. So that eliminates the old weld bolts on the back side caper.. Next option was a bracket that accepted the carriage bolt but also allowed some adjustment side to side. This design was graciously shared with us by Laszlo Nobi (aka Chevynut) as he had done on his 56 Nomad build (see here: https://www.trifivechevys.com/showth...final-assembly ). So we started with 2 x 2 x 1/4" thick square tubing. The 1/4" thickness allows for the height of the "square" of the carriage bolt, and we cut down on the width to just enough for the carriage bolt diameter, both to minimize size of the bracket and also to minimize the tendency for the center of the bracket to pull outward. Square tubing is cut to length and sliced and diced as shown... https://hosting.photobucket.com/imag...y/IMG_8489.JPG https://hosting.photobucket.com/imag...y/IMG_8491.JPG Adjacent parts are beveled to insure full penetration on the 1/4" thick material.. https://hosting.photobucket.com/imag...y/IMG_8492.JPG https://hosting.photobucket.com/imag...y/IMG_8493.JPG A 7/16 hex nut is used to maintain the 3/8 width so our weld does not close up the slot when the weld shrinks while cooling.. https://hosting.photobucket.com/imag...y/IMG_8495.JPG https://hosting.photobucket.com/imag...y/IMG_8496.JPG The part is then cleaned up, here is our finished part that will weld to the back side of the bumper... https://www.youtube.com/watch?v=WFZePcoMK-U Meanwhile Mike has been working on electrical wiring, here getting the interior light wiring in place so we can load up and take to the upholsterer for headliner installation.. https://hosting.photobucket.com/imag...y/IMG_8498.JPG https://hosting.photobucket.com/imag...y/IMG_8502.JPG |
Re: 55 Wagon Progress
Man, it just keeps getting better and more betterer..
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Re: 55 Wagon Progress
Man, she is looking so nice! Congrats on the new to you shop tools! I'm surprised the suv towed that stuff. That first machine looks pretty heavy?
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Re: 55 Wagon Progress
Thanks guys! Ryan, he did say it was a bit "hairy", mainly dealing with A-holes on the road..
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Re: 55 Wagon Progress
The new press brake is up and operational, so I've got two press brakes in the shop available if anyone needs to do last minute Christmas shopping for the wife/girlfriend.. ;)
Brake #1 is Diacro 16-24 MANUAL press brake, 8 ton, SN J-1500. Comes with the home-made stand you see it on, and the dies that are installed. This one has the fully functioning back gauge, a must have for repeat bends. None of the junk laying under or next to it is part of the dealio. Modestly priced at 2100, about half of what they're on eBay for. Diacro makes good product and they hold their value. https://hosting.photobucket.com/imag...y/IMG_8521.JPG https://hosting.photobucket.com/imag...y/IMG_8522.JPG https://hosting.photobucket.com/imag...y/IMG_8524.JPG https://hosting.photobucket.com/imag...y/IMG_8525.JPG https://hosting.photobucket.com/imag...y/IMG_8526.JPG Back gauge in operation: https://www.youtube.com/watch?v=NiSnrZCJC_g Brake #2 is Diacro 16-24 MANUAL press brake, 8 ton, SN J-1353. Comes with the home-made stand you see it on, and the dies that are installed. These are radius dies, two sets. Yes they are different heights, just installed both sets to show them. This one is missing some parts to the back gauge. None of the junk laying under or next to it is part of the dealio. Modestly priced at 1800, about half of what they're on eBay for. Diacro makes good product and they hold their value. https://hosting.photobucket.com/imag...y/IMG_8535.JPG https://hosting.photobucket.com/imag...y/IMG_8530.JPG https://hosting.photobucket.com/imag...y/IMG_8531.JPG https://hosting.photobucket.com/imag...y/IMG_8532.JPG https://hosting.photobucket.com/imag...y/IMG_8533.JPG https://hosting.photobucket.com/imag...y/IMG_8536.JPG If someone would want both, which would assist in fabricating the rest of the backstop for the second brake, package deal for 3750. No shipping, prefer you come and kick the tires. We can load onto your truck/trailer. Located in Leonardtown MD |
Re: 55 Wagon Progress
Lowered price and offered shipping...
Year end sale, last chance for a tax deduction for the year. Diacro 16-24 MANUAL press brake, 8 ton, SN J-1500. Comes with the home-made stand you see it on, and the dies that are installed. This one has the fully functioning back gauge, a must have for repeat bends. None of the junk laying under or next to it is part of the dealio. Modestly priced at 1900, less than half of what similar ones are on eBay for. Stand has a full shelf for storage of dies. These brakes are 24” wide and rated at 16 gauge capacity. Ideal for a small shop or home garage where space is a premium. I would prefer the buyer come and kick the tires, and we can load onto your truck/trailer. Located in Leonardtown Maryland. We can help prep for shipping if needed, buyer pays all shipping costs. I also have a second one if someone would like a package deal.. https://hosting.photobucket.com/imag...y/IMG_8521.JPG https://hosting.photobucket.com/imag...y/IMG_8522.JPG https://hosting.photobucket.com/imag...y/IMG_8524.JPG https://hosting.photobucket.com/imag...y/IMG_8525.JPG https://hosting.photobucket.com/imag...y/IMG_8526.JPG Back gauge in operation: https://www.youtube.com/watch?v=NiSnrZCJC_g |
Re: 55 Wagon Progress
Lowered price, shipping offered, second machine…
Year end sale, last chance for a tax deduction for the year. Diacro 16-24 MANUAL press brake, 8 ton, SN J-1353. Comes with the home-made stand you see it on, and the dies that are installed. These are two sets of radius dies. Yes they are different heights, we just installed both to better display what goes with the machine. This brake is missing some parts of the back gauge. None of the junk laying under or next to it is part of the dealio. Modestly priced at 1600, less than half of what similar ones are on eBay for. Stand has a full shelf for storage of dies. These brakes are 24” wide and rated at 16 gauge capacity. Ideal for a small shop or home garage where space is a premium. I would prefer the buyer come and kick the tires, and we can load onto your truck/trailer. Located in Leonardtown Maryland. We can help prep for shipping if needed, buyer pays all shipping costs. I do have two available if someone would like a package deal. https://hosting.photobucket.com/imag...y/IMG_8535.JPG https://hosting.photobucket.com/imag...y/IMG_8530.JPG https://hosting.photobucket.com/imag...y/IMG_8531.JPG https://hosting.photobucket.com/imag...y/IMG_8532.JPG https://hosting.photobucket.com/imag...y/IMG_8533.JPG https://hosting.photobucket.com/imag...y/IMG_8536.JPG |
Re: 55 Wagon Progress
Well we are about to get started on some automotive electrical work when the wagon returns from Upholstery, and in an attempt to limit/eliminate any need for butt splices, I was looking around for various automotive "W" crimp terminals that were available. I found a gem of a store, www.repairconnector.com that carries much of the old style crimp on terminals, as well as some of the newer stuff. We do have some new light fixtures going in, and to help in eliminating excessive connections (ie: butt splices) I found they carry the replacement terminals for lamp base sockets.. (and terminals for fuse blocks, and.....)
Some of the terminals we just picked up from Repair Connector https://hosting.photobucket.com/imag...y/IMG_8610.jpg Typical replacement light housing has pigtails that will require some type of splice... https://hosting.photobucket.com/imag...y/IMG_8619.JPG New lamp base terminals from Repair Connector https://hosting.photobucket.com/imag...y/IMG_8615.JPG https://hosting.photobucket.com/imag...y/IMG_8616.JPG These terminals will help us get rid of some splices.. https://hosting.photobucket.com/imag...y/IMG_8617.JPG If you have a need to repair/replace any of your automotive electrical wiring, give them a look, they may have something you can use.. |
Re: 55 Wagon Progress
Busy weekend, Norris Upholstery is in the process of getting the door panels done..
https://hosting.photobucket.com/imag...y/IMG_8725.JPG We plan on using the original stainless that was used on the door panels but some of the factory "nails" that get folded over were very fatigued and in some cases, gone.. https://hosting.photobucket.com/imag...y/IMG_8790.JPG To try and fix these we needed a machine that would weld on new nails, which were originally .06 diameter. Using a dent puller stud welder would require resistance welding, which means heat generated. Not good. We have a local sign shop, A&A MetalWorks, that has a Capacitive Discharge stud welder that does not produce the same type of heat.. He did not have the small studs needed so I picked up some of the type that fits the dent puller. Since a collet was needed, Allen dropped off one of his larger collets and Mike became more fluent on a worn out South Bend this weekend, making a collet so we could do a trial run... Here's a collet for a 1/4-20 stud, our sample... https://hosting.photobucket.com/imag...y/IMG_8788.JPG Mike in action.... https://hosting.photobucket.com/imag...y/IMG_8791.JPG https://hosting.photobucket.com/imag...y/IMG_8796.JPG Our fabricated collet, borrowing some parts from the sample... https://hosting.photobucket.com/imag...y/IMG_8798.JPG Testing out the welder, we did have to reshape the ends of the studs to have a point, much like the 1/4-20 sample above, but here are the results.. As you can see there is no appreciable heat introduced into the panel, no heat mark, no distortion. A stress test performed using pliers showed the metal would pull inward and the stud still did not release.. https://hosting.photobucket.com/imag...y/IMG_8832.JPG https://hosting.photobucket.com/imag...y/IMG_8835.JPG Welder in action: https://www.youtube.com/watch?v=MSq_ZX9V2y8 With our trial run complete and deemed a success, Allen is ordering some 14 gauge pins to fit his machine so we won't need to modify them. The size goes up about .01, from .06 to .074, but they seemed plenty malleable to bend over for trim retention. I'll add, these CD stud welders work on steel, stainless, or aluminum. Needing to put a fork in our bumper bolt brackets, the inside slots needed cleanup work and the 12" disc sander seemed ideal for doing such. But some clearance was needed on the machine.. https://hosting.photobucket.com/imag...y/IMG_8772.JPG https://hosting.photobucket.com/imag...y/IMG_8774.JPG https://hosting.photobucket.com/imag...y/IMG_8776.JPG https://hosting.photobucket.com/imag...y/IMG_8778.JPG All ready for welding.. https://hosting.photobucket.com/imag...y/IMG_8840.JPG Lastly, we visited the last known remaining milk truck from the Leonardtown Dairy. It had been sold to a local waterman, who used its refrigeration capability to store crabs and oysters. Needless to say, it wreaked havoc on what remained of the truck, the lower sides had been patched over with galvanized sheet metal long ago. It did give us enough details to capture what we need for lettering/sign painting the Divco, our next shop project. https://hosting.photobucket.com/imag...y/IMG_8800.jpg https://hosting.photobucket.com/imag...y/IMG_8799.jpg https://hosting.photobucket.com/imag...y/IMG_8804.JPG https://hosting.photobucket.com/imag...y/IMG_8811.JPG https://hosting.photobucket.com/imag...y/IMG_8829.JPG |
Re: 55 Wagon Progress
the side of that old milk truck would make some cool wall art...
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Re: 55 Wagon Progress
Greg, the guy that took us down there is in the process of buying as "yard art" and may cut those sides out as billboards... or leave it intact...
The press brakes have been sold, and have left the building... |
Re: 55 Wagon Progress
Time for a wagon update, all of our mounting holes in the bumpers are filled, and the three pieces assembled into one..
https://hosting.photobucket.com/imag...y/IMG_8854.JPG https://hosting.photobucket.com/imag...y/IMG_8896.JPG https://hosting.photobucket.com/imag...y/IMG_8902.JPG We picked up the wagon from upholstery, still needs door panels done so we need to finish stainless trim for them.. Boy that sunlight is like turning on a light switch!! https://hosting.photobucket.com/imag...y/IMG_8873.JPG https://hosting.photobucket.com/imag...y/IMG_8869.JPG How our brackets will work.... https://hosting.photobucket.com/imag...y/IMG_8875.JPG video explanation of our next modification... https://www.youtube.com/watch?v=p6yCAQ5rJPc With brackets clamped in place the "weld locations" are found by starting with centerline of the bumper, adjusting to actual offset of the car, and locating the spacing needed. https://hosting.photobucket.com/imag...y/IMG_8939.JPG Jared and I add some tweaks to fine tune ear placement and test our tig welds at the same time.. https://hosting.photobucket.com/imag...y/IMG_8936.JPG In the meantime, Mike is doing some cleanup of the door stainless, bumping up dings, filing, and taking to a Trizact 5000 finish. Then we'll get the studs welded on and final polish.. https://hosting.photobucket.com/imag...y/IMG_8938.JPG https://hosting.photobucket.com/imag...y/IMG_8937.JPG |
Re: 55 Wagon Progress
Looks great Robert...that thing really does shine in the sun...
That's some serious "adjustment " on the bumper..brings back memories of when I was working on the IH bumper...I was amazed at how much springback was in the bumper.. |
Re: 55 Wagon Progress
Great work as always...Jim
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Re: 55 Wagon Progress
Thanks fellas!
Back to our door panel stainless, the correct studs came in for the CD stud welder, and tests have shown them to provide the solution we need.. https://hosting.photobucket.com/imag...y/IMG_8938.JPG These studs have much less mass at the end, for a lesser capacitive charge needed. https://hosting.photobucket.com/imag...y/IMG_8951.JPG https://hosting.photobucket.com/imag...y/IMG_8952.JPG Tested on a piece of 19 gauge steel, note the back side has no discoloration whatsoever. Allen used a pair of Vise grips to give it a twist test to see if the weld would release. Where the one that is cut got too close to the cutters, the others did not release, and in fact distorted the shape of the metal because they held so well. The one pin shows a good 90* bend, which is what will be used to hold the stainless onto the door panel per the same design as original. https://hosting.photobucket.com/imag...y/IMG_8967.JPG https://hosting.photobucket.com/imag...y/IMG_8968.JPG https://hosting.photobucket.com/imag...y/IMG_8969.JPG And now for the next wrench thrown in our bumper modifications.. Welding causes shrinking, so TIG welding the slotted brackets onto the back side of the bumper invariably causes flat spots on the front side of where the brackets reside.. So some quick work on the South Bend to make a purpose built punch so we can do some metal bumping on the bumper.. https://hosting.photobucket.com/imag...y/IMG_8965.JPG https://hosting.photobucket.com/imag...y/IMG_8966.JPG https://hosting.photobucket.com/imag...y/IMG_8984.JPG https://hosting.photobucket.com/imag...y/IMG_8985.JPG https://hosting.photobucket.com/imag...y/IMG_8986.JPG ….or the motion picture visual.... https://www.youtube.com/watch?v=dH5F7VZRwvI And after a bit of metal bumping, we have the area down to less than a 1/32 depression, which should be just fine for the copper stage of plating.. https://hosting.photobucket.com/imag...y/IMG_8992.JPG Note the minimal gap behind the straightedge. One down, three to go... https://hosting.photobucket.com/imag...y/IMG_8993.JPG |
Re: 55 Wagon Progress
Robert, Its a small world! I saw the corner of the orange paper where you bought the latest weld-studs. That place is 15 min. from me! Im in Wexford on a regular basis. Always looking forward to your latest update. Lorne
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Re: 55 Wagon Progress
Thanks Lorne! Yeah, those weld studs work awesome! Hope to get back to A&A Signs next week to finish them up...
In another back up and punt moment, we found some interference with the new bumper brackets and the rear tailpan. In order to tuck things in nice and close, we need to trim a portion of the rear channel in the tail pan. Nothing a pair of tin snips and a file can't resolve. Pay no attention to that green paint. The bare edges will be touched up with SPI epoxy primer.. https://hosting.photobucket.com/imag...y/IMG_9028.JPG https://hosting.photobucket.com/imag...y/IMG_9052.JPG https://hosting.photobucket.com/imag...y/IMG_9053.jpg Our final test fit on the back bumper before chroming: https://www.youtube.com/watch?v=MzeOzhcYrSg On to our tail light hidden fuel fill...… https://www.youtube.com/watch?v=848V2PbuQJw This thing had been giving us fits in intermittent operation, and it hasn't even been exposed to water yet. Looking at the wiring (why can't we keep the colors consistent through?)….. https://hosting.photobucket.com/imag...y/IMG_9058.JPG Well this isn't part of the problem... found a couple loose terminals.. https://hosting.photobucket.com/imag...y/IMG_9056.JPG https://hosting.photobucket.com/imag...y/IMG_9060.JPG So we decided to eliminate the original trailer connector and term board connections and replace with Weather Pack connectors. The relays will be mounted behind the rear seat for a closer proximity to the tail light, and the DPDT toggle switch will be replaced with a DPDT momentary rocker. https://hosting.photobucket.com/imag...y/IMG_9057.JPG https://hosting.photobucket.com/imag...y/IMG_9061.JPG On a side note, a recent task for the day job involved some cherry trim boards that were pre-stained and we had difficulty finding a match using Minwax blend-fill pencils. The Number 3, 5, and 6 were all off.... https://hosting.photobucket.com/imag...y/IMG_9012.JPG However, kneading the 3 and 5 together showed promise. But how to do that on a larger, less time consuming scale. I will say none of the wife's wax melting pots were harmed in this experiment, but the trim screw holes in stained trim were all but invisible when done. The pencils were unwrapped, cut up into 1" lengths, then melted and mixed together. In case someone else needs to do the same... https://hosting.photobucket.com/imag...y/IMG_9013.JPG |
Re: 55 Wagon Progress
Robert,,, that fuel fill is cool....sounds like a robot.....cant wait to see that bumper in chrome..
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Re: 55 Wagon Progress
Thanks Greg, let's just hope there's never any electrical failures when the fuel needs filling.. ;)
So part of our fitment exercises with the bumpers has been to get them in a little closer to the body for more consistent gaps to the body. The rear bumper had it's challenges with needing to notch out the lower lip of the tailpan. https://hosting.photobucket.com/imag...y/IMG_9052.JPG https://hosting.photobucket.com/imag...y/IMG_9053.jpg https://hosting.photobucket.com/imag...y/IMG_9028.JPG https://hosting.photobucket.com/imag...y/IMG_9029.JPG https://hosting.photobucket.com/imag...y/IMG_9030.JPG The front would be no different. The front nose of the frame rails was hitting the rear side of the factory brackets and preventing us from locating the bumper for a good consistent gap.. https://hosting.photobucket.com/imag...y/IMG_9120.JPG So some modification was in order so that the frame horn could fit in closer to the rear side of the bumper.. https://hosting.photobucket.com/imag...y/IMG_9121.JPG We now have a much better fit.. https://hosting.photobucket.com/imag...y/IMG_9138.JPG https://hosting.photobucket.com/imag...y/IMG_9140.JPG https://hosting.photobucket.com/imag...y/IMG_9141.JPG https://hosting.photobucket.com/imag...y/IMG_9142.JPG |
Re: 55 Wagon Progress
Details details..!!...those are gonna look great when they get shiny..
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Re: 55 Wagon Progress
Awesome work. That green paint is killer too.
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Re: 55 Wagon Progress
Quote:
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So we've started on our wiring, what can go wrong? First item on the list is the interior lights, we had run the wires before the headliner went in. We had installed a second light just behind the rear seat and the plans were to gang it to the front light by putting two wires into a 12 gauge pin in the weatherpack connector. This should be a 5 minute job. Only the weatherpack connector would not fit inside the void in the ceiling. Since we don't intend on using butt splices, we had tried installing two wires previously into the w-crimp lamp base contacts as shown: https://hosting.photobucket.com/imag...y/IMG_8624.JPG https://hosting.photobucket.com/imag...y/IMG_8626.JPG This sample we did using the red Teflon insulation fit inside the brass "tubes" of the lamp base perfectly. But the insulation on AAW wiring is much thicker. Ahhh, the dominoes they do fall. So let's see what we can do to modify the brass tubes to better accept the wiring going in. Our local Ace hardware has a good selection of "model" tubing in aluminum and brass, so with fingers crossed, we picked up the 3/16 size. https://hosting.photobucket.com/imag...y/IMG_9155.JPG The ID measured out to .154, about .010 larger than what the lamp base came with. The outside diameter of the tube was turned down on the lathe to a size that would play nice inside the plastic housing and not bind on the spring. https://hosting.photobucket.com/imag...y/IMG_9148.JPG Some aluminum bar stock was drilled with a tight clearance hole for our new tube, and served as a fixture to swage one end for spring retention. Sorry, missed pictures of some of the details (fire the photographer). The opposite end was swaged after insertion into the housing.. https://hosting.photobucket.com/imag...y/IMG_9154.JPG https://hosting.photobucket.com/imag...y/IMG_9153.JPG With the tubes now sized for two wires, we got the front light installed. The rear light and its single wires should now be a breeze. https://hosting.photobucket.com/imag...y/IMG_9156.JPG https://hosting.photobucket.com/imag...y/IMG_9157.JPG |
Re: 55 Wagon Progress
Progress from yesterday, while Jared was blocking out some of the window garnish moldings, I worked on the door panel stainless trim to ready them for stud welding. Mike had used the trim repair tool to remove the dings, which were then filed smooth.
https://hosting.photobucket.com/imag...y/IMG_8938.JPG The last 65 years had left their mark; we had numerous scratches needing removal as well. We started with 320 grit on the fine pattern palm sander, and progressed our way up to 8000 grit trizact.. https://hosting.photobucket.com/imag...y/IMG_9202.JPG https://hosting.photobucket.com/imag...y/IMG_9203.JPG https://hosting.photobucket.com/imag...y/IMG_9204.JPG https://hosting.photobucket.com/imag...y/IMG_9205.JPG https://hosting.photobucket.com/imag...y/IMG_9206.JPG This is the final using the 8000 grit, and we'll start the buffing process once the stud welding had been completed.. https://www.youtube.com/watch?v=n5YYWcQgIRg With the stainless prepped, we turned attention to the window garnishes. They were sprayed with three coats of SPI epoxy. https://hosting.photobucket.com/imag...y/IMG_9211.JPG https://hosting.photobucket.com/imag...y/IMG_9215.JPG Today we went to A&A Metalworks in Ridge MD to get the studs welded in place. This sample shows the studs, where three have been folded over to a 90. This is how the factory held them onto the door panels as well. Note the back side shows no heat pattern with the Capacitive Discharge welder. https://hosting.photobucket.com/imag...y/IMG_9217.JPG https://hosting.photobucket.com/imag...y/IMG_9218.JPG Welding the studs onto the stainless trim... https://www.youtube.com/watch?v=7WZ25tqOXos Our results... https://www.youtube.com/watch?v=YXQCJe1hma8 A test to check the heat the welder introduces into the panel.. https://www.youtube.com/watch?v=DkDRJXstvH4 This shows these welders make a good choice to use where cases of heat sensitivity may be an issue. |
Re: 55 Wagon Progress
Happy Easter everyone!
Our wagon progress from this weekend, we finished up the interior lights. Here wiring up the rear light. The included pigtails were discarded to eliminate a butt splice, and our newly installed wiring made use of new lamp base contacts (W crimp) from Repair Connector. https://hosting.photobucket.com/imag...y/IMG_9257.JPG https://hosting.photobucket.com/imag...y/IMG_9259.JPG The lens used in light fixtures like these are typically plagued over the years by overheating and then cracking, so we opted for a 1004 LED replacement. Should keep things cooler for longer lens life, and brighter!! https://hosting.photobucket.com/imag...y/IMG_9264.JPG https://hosting.photobucket.com/imag...y/IMG_9260.JPG Onto more electrical issues, the "hidden fuel door" we had purchased was so intermittent in operation that when we had dropped it off at Absolute Rod & Custom Paint to test fit to the car when they were fine tuning the bodywork, we were second guessing whether we should use it at all. https://www.youtube.com/watch?v=848V2PbuQJw All the harnesses came into a terminal board with wires going to the relays on the opposite side. Some of the terminals had as many as three wires in them, and Mike Flores found about 6 loose wires. Splices didn’t carry the same wire color through, making trouble shooting a bit of a challenge. The toggle switch (which should have been momentary contact but was not) had some home-made fork terminals. This thing was looking more sketchy with everything we looked at next. For a store-bought product intended for an automotive environment, they should find someone more competent in wiring. https://hosting.photobucket.com/imag...y/IMG_9056.JPG https://hosting.photobucket.com/imag...y/IMG_9058.JPG To get rid of the terminal board, we opted for weather pack connectors, one to each of the end terminations (switch, fuel door, power source). We eliminated the triple wires to single terminal by jumpering, making use of two wires in a single pin, and jumpered as required. https://hosting.photobucket.com/imag...y/IMG_9265.JPG https://hosting.photobucket.com/imag...y/IMG_9266.JPG https://hosting.photobucket.com/imag...y/IMG_9267.JPG Our new wires going into the relay connectors made use of new Packard 56 style female spade terminals from www.repairconnector.com (more W-crimp) These were also jumpered two wires to a pin where needed. https://hosting.photobucket.com/imag...y/IMG_9271.JPG https://hosting.photobucket.com/imag...y/IMG_9272.JPG The toggle switch was replaced by an automotive grade MOMENTARY rocker switch from McMaster. Works flawlessly. https://hosting.photobucket.com/imag...y/IMG_9275.JPG https://www.youtube.com/watch?v=wxGo6JU19kY Not pretty, but much improved. The relays will be located behind the rear seat on the sub box, conveniently between all our end points. Just like our speaker grilles, black plastic really doesn't belong in plain view in a 55 Chevy. So our more highly functional rocker switch will be hidden inside the glove box.. |
Re: 55 Wagon Progress
So now that I'm back from the short hiatus in Albuquerque, hanging TV's for the day job... We did get to see some sights, here's cars and coffee attendees on April 17th..
https://hosting.photobucket.com/imag...y/IMG_9392.JPG https://hosting.photobucket.com/imag...y/IMG_9394.JPG https://hosting.photobucket.com/imag...y/IMG_9395.JPG https://hosting.photobucket.com/imag...y/IMG_9396.JPG https://hosting.photobucket.com/imag...y/IMG_9397.JPG https://hosting.photobucket.com/imag...y/IMG_9400.JPG https://hosting.photobucket.com/imag...y/IMG_9407.JPG https://hosting.photobucket.com/imag...y/IMG_9409.JPG https://hosting.photobucket.com/imag...y/IMG_9410.JPG https://hosting.photobucket.com/imag...y/IMG_9415.JPG https://hosting.photobucket.com/imag...y/IMG_9416.JPG https://hosting.photobucket.com/imag...y/IMG_9417.JPG Later that same day we rolled past the car wash from Breaking Bad fame... https://hosting.photobucket.com/imag...y/IMG_9419.JPG |
Re: 55 Wagon Progress
The following weekend we ventured to Moriarity NM to the Lewis Antique Auto and Toy Museum. Heaven on earth...
The inside stuff.... https://hosting.photobucket.com/imag...y/IMG_9554.JPG a 427-8V powered 57 T-bird https://hosting.photobucket.com/imag...y/IMG_9555.JPG https://hosting.photobucket.com/imag...y/IMG_9558.JPG https://hosting.photobucket.com/imag...y/IMG_9562.JPG Some of the treasures outside.... https://hosting.photobucket.com/imag...y/IMG_9567.JPG https://hosting.photobucket.com/imag...y/IMG_9568.JPG https://hosting.photobucket.com/imag...y/IMG_9578.JPG https://hosting.photobucket.com/imag...y/IMG_9587.JPG https://hosting.photobucket.com/imag...y/IMG_9588.JPG https://hosting.photobucket.com/imag...y/IMG_9611.JPG https://hosting.photobucket.com/imag...y/IMG_9615.JPG https://hosting.photobucket.com/imag...y/IMG_9629.JPG Give me the old stuff over the new... https://hosting.photobucket.com/imag...y/IMG_9613.JPG Alas, all of these goodies were part of the museum and not for sale. We did spend about 4 hours there taking in the sights, even still... |
Re: 55 Wagon Progress
Nice old stuff..!
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Re: 55 Wagon Progress
Super cool...Jim
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Re: 55 Wagon Progress
This past Saturday I went to the Jalopyrama show, held at the Talbot County Community Center in Easton, MD. I made a stop off at the parking lot of the Double T Diner in Parole, MD first though, had to finalize an online purchase of these two gems...
https://hosting.photobucket.com/imag...y/IMG_9889.JPG https://hosting.photobucket.com/imag...y/IMG_9888.JPG Should be some good overflow storage for the Lennox dies.. Here are some of the pictures from the show.. The Willys Woodie is a one of 6 made. https://hosting.photobucket.com/imag...y/IMG_9884.JPG https://hosting.photobucket.com/imag...y/IMG_9883.JPG https://hosting.photobucket.com/imag...y/IMG_9876.JPG https://hosting.photobucket.com/imag...y/IMG_9878.JPG https://hosting.photobucket.com/imag...y/IMG_9858.JPG https://hosting.photobucket.com/imag...y/IMG_9861.JPG https://hosting.photobucket.com/imag...y/IMG_9863.JPG https://hosting.photobucket.com/imag...y/IMG_9864.JPG https://hosting.photobucket.com/imag...y/IMG_9865.JPG https://hosting.photobucket.com/imag...y/IMG_9829.JPG https://hosting.photobucket.com/imag...y/IMG_9830.JPG https://hosting.photobucket.com/imag...y/IMG_9841.JPG https://hosting.photobucket.com/imag...y/IMG_9853.JPG https://hosting.photobucket.com/imag...y/IMG_9855.JPG https://hosting.photobucket.com/imag...y/IMG_9857.JPG Cody Walls had two cars there in bare steel, badass to say the least. The Buick has been sectioned and roof pancaked, the 32 is heavily channeled. https://hosting.photobucket.com/imag...y/IMG_9869.JPG https://hosting.photobucket.com/imag...y/IMG_9881.JPG https://hosting.photobucket.com/imag...y/IMG_9886.JPG https://hosting.photobucket.com/imag...y/IMG_9846.JPG https://hosting.photobucket.com/imag...y/IMG_9850.JPG This show is always a must see, and this year did not disappoint.. |
Re: 55 Wagon Progress
Well after about two months of travel for the day job, hangin TV's....
https://youtu.be/Kw1LEhtzkP8 …..we finally got back to work on the wagon and some long overdue progress. The lift gate has been outfitted with some stainless prop rods... https://hosting.photobucket.com/imag...y/IMG_9302.JPG Jared has been working on blocking some of the window garnish moldings, and found some low spots. The long sections on many of these when made at the factory were fabricated in multiple pieces and butt welded together in much the same fashion as band saw blades. The front, exposed side would be sanded smooth and the rear side shows a line of weld slag. (see red outlined circle) https://hosting.photobucket.com/imag...y/IMG_9305.jpg So we had a couple that showed low areas, but could not readily metal bump with the slag on the back side.. So another tool was made with a notch to accommodate the weld line.... https://hosting.photobucket.com/imag...y/IMG_9311.JPG This allowed us to bump up the low areas... https://hosting.photobucket.com/imag...y/IMG_9307.JPG ….and.....more.....blocking...…. https://hosting.photobucket.com/imag...y/IMG_0197.JPG https://hosting.photobucket.com/imag...y/IMG_0200.JPG And we also got started on the fabrication of the fan shroud. Just as with patch panels, you will in most cases find it easier and quicker to make challenging parts in multiple pieces and weld the parts together. Then in other cases you want to try something to see if you can.... I give you one piece fan shroud. https://hosting.photobucket.com/imag...y/IMG_0161.JPG https://hosting.photobucket.com/imag...y/IMG_0162.JPG https://www.youtube.com/watch?v=qJm_xZ8dEnw Getting real close... https://hosting.photobucket.com/imag...y/IMG_0208.JPG Needs a bit more work with the linear stretch dies to add some more circumference. Then we will add some bead details and a wired edge for strength. To show how much stretching we've done, the metal has gone from .044 thick to .030 at the flange edge... https://hosting.photobucket.com/imag...y/IMG_0181.JPG https://hosting.photobucket.com/imag...y/IMG_0212.JPG And Mike was busy with buttoning up loose ends that we can do a test fire, hopefully this coming weekend, if we can get a parts delivery before then. https://hosting.photobucket.com/imag...y/IMG_0198.JPG |
Re: 55 Wagon Progress
Fan shroud work is amazing to see Robert..I'd have to make that in 20 pcs..
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Re: 55 Wagon Progress
The next couple of posts will seem more of a lessons learned than progress of any sort.. Back in my youth many decades ago I was witness to what occurs when one of your siblings was too big for her britches and back talked my father. A quick back hand and she didn't do that again. From that day on, I have been a firm believer in learning from other's mistakes, so hold on and enjoy the ride. It isn't too painful..
With the fan shroud formed it was time for a bead from the bead roller, and we planned on a wired edge to add strength, concentricity, and improve the looks. From dimensions taken from the rear flange of the core support (our fan shroud mounting location) to the center of the fan worked out to about 1-3/4". So given that height, these are the dimensions we came up with for our beadwork.. Typical wrap for the wire edge is 2.5X the diameter of the wire, so given 3/16 wire our flange for wrapping should be .468 or thereabouts.. https://hosting.photobucket.com/imag...y/IMG_0248.JPG The bead roller die that matches our wire edge size was not correctly dimensioned to be able to use as a backstop, so some "filler" in the form of rare earth magnets gave us the dimension we were looking for.. https://hosting.photobucket.com/imag...y/IMG_0222.JPG https://hosting.photobucket.com/imag...y/IMG_0251.JPG So using the bead roller and the joggle dies from the Biederman hood sides, the bead/wire edge was added to our test sample. https://hosting.photobucket.com/imag...y/IMG_0253.JPG https://hosting.photobucket.com/imag...y/IMG_0256.JPG https://hosting.photobucket.com/imag...y/IMG_0257.JPG https://hosting.photobucket.com/imag...y/IMG_0263.JPG That looked about spot on, so the bead roller was used to add the center bead on the fan shroud, and the edge was cut to size and tipped to a 90* angle.. https://hosting.photobucket.com/imag...y/IMG_0269.JPG https://hosting.photobucket.com/imag...y/IMG_0271.JPG https://hosting.photobucket.com/imag...y/IMG_0274.JPG Now to use our joggle dies to add the outer bead detail.... which looks like the shroud mounting flange is in the way.. Did I say one piece fabrication was harder? https://hosting.photobucket.com/imag...y/IMG_0291.JPG So a new die is in order, for the bottom we have a sliding lower toolholder so that will accommodate most of the offset there. for the top, we need to stack some dies to get the offset needed. https://hosting.photobucket.com/imag...y/IMG_0300.JPG https://hosting.photobucket.com/imag...y/IMG_0303.JPG The upper die also needed a 45* relief on the bottom for installing the lower die. https://hosting.photobucket.com/imag...y/IMG_0307.JPG https://hosting.photobucket.com/imag...y/IMG_0309.JPG Looks much better... https://hosting.photobucket.com/imag...y/IMG_0311.JPG https://hosting.photobucket.com/imag...y/IMG_0316.JPG Our speed run... https://www.youtube.com/watch?v=nyylI6tybew .....and this happens on the last pass.. https://hosting.photobucket.com/imag...y/IMG_0317.JPG |
Re: 55 Wagon Progress
So now for some hindsight. When we had done a flat test sample we noticed the edge of the lower die had made a crease (finger point). To alleviate this, I will normally taper the dies so the edges aren't tight together, in hopes of curing exactly that.
https://hosting.photobucket.com/imag...y/IMG_0320.JPG https://hosting.photobucket.com/imag...y/IMG_0318.JPG Looking back, this slight defect would have been at the edge of the center bead and likely not noticeable at all. Next, between this taper and the ~1/2" flange not wanting to stretch, the resulting shape matches the bottom die, and pulls the shroud circumference inward.. which was not desired either. So moving forward, rather than a folded flange here we should opt for an offset first for more flexibility in stretching outward for the bead detail, and then fold the flange last. https://hosting.photobucket.com/imag...y/IMG_0319.JPG So given our misshapen and slit open fan shroud is no longer viable, what's a person to do? I'm not one to so easily throw in the towel. More accurately, I've been called hard headed. So here we go with the second take of Fan Shroud fabrication. And since we missed this step last time, take a look at this video having just cut out the center hole.. https://www.youtube.com/watch?v=hakmD7Wn4f8 There were absolutely ZERO burrs as can be seen. If your tin snip game is not at this level, please watch this instructional video by my friend and fellow metalshaper Bill Gibson. He will explain exactly what you need to do for the same results... https://www.youtube.com/watch?v=qAOQfUaRZyw I had been using tin snips for DECADES and watched this video, quickly learning what I had been doing wrong for so long... ....and then back on the NEW fan shroud, stretch with a blocking hammer on the stump, tip the edge, stretch again, until we are able to get the shroud into the power hammer... https://hosting.photobucket.com/imag...y/IMG_0343.JPG https://hosting.photobucket.com/imag...y/IMG_0341.JPG https://hosting.photobucket.com/imag...y/IMG_0366.JPG and using the power hammer.... https://www.youtube.com/watch?v=NqGRLIFKQ1o https://www.youtube.com/watch?v=FyCR6sI8TUU Getting close, we're down to about 10% more to go... https://hosting.photobucket.com/imag...y/IMG_0388.JPG In between all that fiasco, Mike was working on getting the car test fired. All the temporary wiring connected, and for some reason we had no fuel pump action. OK, third time we've dropped the tank in a week, and removing the pump we find NO connectivity from the outside ground to the inside ground. WTF? https://hosting.photobucket.com/imag...y/IMG_0409.JPG Lo and behold, there is no pass through on the grounds but each (inside and outside) has their own bottom tapped hole. It would appear the tapping occurred PRIOR to the anodize finish, and you know how well that conducts.. The burnishing brushes wouldn't touch the stuff, so we used some sharp implements of destruction to allow a ground path... https://hosting.photobucket.com/imag...y/IMG_0410.JPG https://hosting.photobucket.com/imag...y/IMG_0412.JPG That fixed the issue, one that should not have been there from the start. Next, in the interest of safety, lets move the rear "lift kit" from the tires to just inboard using jack stands.. https://hosting.photobucket.com/imag...y/IMG_0413.JPG https://hosting.photobucket.com/imag...y/IMG_0414.JPG So now with a bit of fuel pressure to work with, we give you a rumble... We still need to adjust the air/fuel ratio but it was good to hear this after everything else the past couple weeks.. https://www.youtube.com/watch?v=MoIjmmmXtO0 |
Re: 55 Wagon Progress
great news on the test fire...and as always Robert, yall are doing amazing work..maybe round 2 will work out for ya
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Re: 55 Wagon Progress
Thanks Greg!
More progress on the (second) fan shroud, but I had a request to show the process in greater detail.. So we'll start with the beginning. First was the layout of the bend line, and then the cut line was located about 3" inside of that. (I'm using some of the pictures from our first attempt as our shop photographer missed some the second time around) https://hosting.photobucket.com/imag...y/IMG_0162.JPG The initial stretch was done using a blocking hammer on the top (flat area) of the stump, primarily at the inside edge as that needed the most stretch. https://hosting.photobucket.com/imag...y/IMG_0441.JPG On our first attempt we had a hammer form that was used to "set" the bend line with a crowned body hammer as we added the first bit of stretch. https://hosting.photobucket.com/imag...y/IMG_0451.JPG This seemed a bit cumbersome, and the second version I used a bent portion of round stock that was in the scrap pile, added a piece of pipe for a handle, and the band saw added a slice for a new tipping tool. The bend in the tipping tool gave it a built in fulcrum. Normally a tipping operation tries to pull the adjacent material along as the bend forms. In this case we set the panel on a table and used the bend (fulcrum) of the tipping tool against the table to pull the stretched area downward. This allows us to push down on the handle to elevate the panel off the table, and to push downward on the flat panel outside the bend line with the palm of your hand. This does a good job of placing the bend where needed without pulling adjacent metal along for the ride. Even though the pictures show the stretched area upward, the panel was placed with this area downward when using the tipping tool.. https://hosting.photobucket.com/imag...y/IMG_0341.JPG https://hosting.photobucket.com/imag...y/IMG_0342.JPG https://hosting.photobucket.com/imag...y/IMG_0343.JPG This worked much better at setting the bend line than the hammer form, and it was surprisingly accurate. Much of the stretch was done using linear stretch dies on the power hammer, but we also reverted back to the blocking hammer and stump to better focus the stretch locations. https://www.youtube.com/watch?v=FyCR6sI8TUU https://www.youtube.com/watch?v=bKBy-TmkrMM https://hosting.photobucket.com/imag...y/IMG_0442.JPG The other issue to overcome with both hammer operations was that they didn't play nice with keeping the shroud in a flat vertical. So the next tool used was a 90 durometer pad of polyurethane and the Model A leaf spring hammer. The hammer face was too short to match the shroud height (approx 3") so three passes were done to cover the entire height and with each pass the hammer hits were about 1/8" or so apart. https://hosting.photobucket.com/imag...y/IMG_0443.JPG https://hosting.photobucket.com/imag...y/IMG_0444.JPG https://hosting.photobucket.com/imag...y/IMG_0445.JPG https://hosting.photobucket.com/imag...y/IMG_0446.JPG The bulk of the stretch was done on the power hammer, and the front of the lower die holder is missing quite a bit of paint from this job... https://hosting.photobucket.com/imag...y/IMG_0447.JPG The completed bend, we started with .044 thickness (18 gauge) and it was thinned to .029 thick, or lost about 1/3 thickness to turn the 90... https://hosting.photobucket.com/imag...y/IMG_0437.JPG https://hosting.photobucket.com/imag...y/IMG_0438.JPG https://hosting.photobucket.com/imag...y/IMG_0439.JPG https://hosting.photobucket.com/imag...y/IMG_0440.JPG https://www.youtube.com/watch?v=IdSQFxGBoZs |
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