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Re: 55 Wagon Progress
The hinge covers for the wagon is one of the many loose ends we have left to address, quite a bit of rust...
https://hosting.photobucket.com/imag...y/IMG_5163.JPG A quick test fit before we go off fabricating anything shows these factory original parts are no better than many of the reproduction parts you get today.. I had planned on fabrication work, didn't know we needed a redesign. https://hosting.photobucket.com/imag...y/IMG_5168.JPG https://hosting.photobucket.com/imag...y/IMG_5169.JPG https://hosting.photobucket.com/imag...y/IMG_5171.JPG We ordered a piece of round stock to match the radius to use on the Magnetic brake, that should arrive Tuesday. Next, we need to fold a hem for our stainless edge trim we plan on using for the ribbed stainless dash insert. The magnetic brake leaves a bit to be desired in having balls enough to hem a short return flange, so we packed up our sheet metal strips we had cut to size and went to another local metalshaper's shop to make use of his apron brake. https://hosting.photobucket.com/imag...y/IMG_5177.JPG https://hosting.photobucket.com/imag...y/IMG_5176.JPG A piece of .030 aluminum acted as a spacer to maintain our hem gap. The brake worked well but the parts needed a bit more flatness to provide nice crisp details. Since he also had a powered Mittler Bros. bead roller, we used some flat dies and ran through all the bent pieces. https://www.youtube.com/shorts/hrFMqEeRhAw test fit of the ribbed stainless.... https://hosting.photobucket.com/imag...y/IMG_5181.JPG https://hosting.photobucket.com/imag...y/IMG_5182.JPG And for a teaser of how it will look after polishing.... https://www.youtube.com/shorts/GfqiYbIZYvo |
Re: 55 Wagon Progress
Great work...Jim
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Re: 55 Wagon Progress
Thanks Jim!
We had a customer bring in a "Patent Idea Display". This had a battery pack inside that powered the headlights (headlight bezels not shown) and featured a rod down the bottom that would oscillate the left headlight, and I believe would flash that headlight as well (based on linkage tied to a relay inside). The control switch is actually the left half of a Model T instrument cluster. https://hosting.photobucket.com/imag...y/IMG_4085.JPG https://hosting.photobucket.com/imag...y/IMG_4086.JPG https://hosting.photobucket.com/imag...y/IMG_5152.JPG https://hosting.photobucket.com/imag...y/IMG_5149.JPG It has obviously had parts (hood) that went missing over the years and an aluminum flashing replacement had been added. He wanted a hood fabricated that looked more period correct, so we offered to do louvers and a faux hinge at the top. For the hood we used 19 gauge AKDQ, and for the louvers we are using the Diacro press brake. The louver dies weren't tall enough for the Diacro, so an adapter was used at the top to make up the difference. https://hosting.photobucket.com/imag...y/IMG_4651.JPG Our practice punches worked fine, but the machine did not have enough depth to the vertical supports of the press brake for the size of our hood. We would need to get sketchy. Real sketchy. With only about half of each die in the machine, and two set screws holding on for dear life.... https://hosting.photobucket.com/imag...y/IMG_4746.JPG https://hosting.photobucket.com/imag...y/IMG_4748.JPG https://youtu.be/2ktrqMyY2VQ https://hosting.photobucket.com/imag...y/IMG_4753.JPG With louvers punched, we used the highly technical argon bottle radius brake to add our hoop. next on the list was to make our hinge using a piece of 1/4" stainless tubing. https://hosting.photobucket.com/imag...y/IMG_4833.JPG https://hosting.photobucket.com/imag...y/IMG_4844.JPG https://hosting.photobucket.com/imag...y/IMG_4843.JPG Next, our hood needs the beltline bead to match cars of the era, and to simulate the hidden hinges for the hood sides. https://youtu.be/Vm47BL7zQ8g Our "hinge" was plug welded in place... https://hosting.photobucket.com/imag...y/IMG_5121.JPG https://hosting.photobucket.com/imag...y/IMG_5122.JPG Media blasted for better paint adhesion, and ready for delivery.. https://hosting.photobucket.com/imag...y/IMG_5124.JPG https://hosting.photobucket.com/imag...y/IMG_5125.JPG |
Re: 55 Wagon Progress
that is cool as all heck..!!!!!...nice work.!!
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Re: 55 Wagon Progress
Great Job again.
You have the best ideas and designs.:metal: |
Re: 55 Wagon Progress
Tying up some loose ends, We still need to finish the wiring at the back of the car, but in the middle of modifying the tail light fixtures for bulb relocation. To that end, in an attempt to keep grounding issues to a minimum, quick disconnect tabs are silver soldered to the tail light housings.
https://hosting.photobucket.com/imag...y/IMG_5356.JPG Next, we started the installation of the rear power windows. The rear motors had been mocked up a couple of times and the screw holes in the plastic housings were loose/borderline stripped. So they were drilled and tapped, and 10-32 heli-coils installed for a more permanent solution. https://hosting.photobucket.com/imag...y/IMG_5354.JPG https://hosting.photobucket.com/imag...y/IMG_5355.JPG Once the power window track was installed, the OEM stop block for downward travel of the window was found to be useless as the window bottomed out into the wheelwell. Some delrin was cut to size, notched for a snug fit onto the track, and two holes drilled for attachment to the track. Worked well... https://hosting.photobucket.com/imag...y/IMG_5426.JPG https://hosting.photobucket.com/imag...y/IMG_5422.JPG https://hosting.photobucket.com/imag...y/IMG_5429.JPG https://www.youtube.com/shorts/vjqXa3sq7D0 While here at the rear window, we still needed to drill mounting holes for the shoulder harness through the window garnish moldings. A 1/2-13 bolt was used to fabricate a threaded hole spotter on the lathe, complete with flats for wrench installation. https://hosting.photobucket.com/imag...y/IMG_5435.JPG https://hosting.photobucket.com/imag...y/IMG_5437.JPG With garnish molding positioned, a quick tap of the dead blow hammer gives an exact location for the hole. https://hosting.photobucket.com/imag...y/IMG_5439.JPG https://hosting.photobucket.com/imag...y/IMG_5451.JPG Next, in order that we don't leave an unfinished hole edge, a punch set was machined for the lathe, complete with stepped shoulders to prevent any movement in the jaws when pressure was applied. This will swage the hole edge for a nice inward flange... https://hosting.photobucket.com/imag...y/IMG_5442.JPG https://www.youtube.com/watch?v=-ZLbmvCv3kk https://hosting.photobucket.com/imag...y/IMG_5455.JPG https://hosting.photobucket.com/imag...y/IMG_5458.JPG https://hosting.photobucket.com/imag...y/IMG_5459.JPG And we had received our new shipment of Cubitron H/L paper from Three Mules Welding Supply for dressing out stainless, so Jared continued prepping our edge trim parts. https://hosting.photobucket.com/imag...y/IMG_5421.JPG Where the hemming process we used with the bead roller isn't an exacting science, we did have some variance in the gap opening that made the prepping process a challenge. In order to get more consistency in gap width, (and thus flange flatness) a new widget tool was fabricated out of 16 gauge to open up those tight spots. https://hosting.photobucket.com/imag...y/IMG_5416.JPG https://hosting.photobucket.com/imag...y/IMG_5417.JPG https://www.youtube.com/shorts/6FTmd8KPPu8 . |
Re: 55 Wagon Progress
More progress on the dash inset. In order to form the outer edge trim to fit, we made an "anvil" out of 19 gauge that match the dash inset. The excess flange was trimmed in the area of the sharp bend.
https://hosting.photobucket.com/imag...y/IMG_5530.JPG https://hosting.photobucket.com/imag...y/IMG_5531.JPG https://hosting.photobucket.com/imag...y/IMG_5532.JPG Some heat was applied to the bend area, slight persuasion added to bend a few degrees, the area flattened to remove any puckers, and repeat. https://hosting.photobucket.com/imag...y/IMG_5533.JPG https://hosting.photobucket.com/imag...y/IMG_5545.JPG Then we needed to shrink the flange on the insides to match the opening. This was accomplished by squeezing the two edge trim ends together, adding a patch of heat to form a tuck, and then flatten out the tucks to provide the shrink. https://youtu.be/mDUlnW5rNSA https://hosting.photobucket.com/imag...y/IMG_5536.JPG https://hosting.photobucket.com/imag...y/IMG_5538.JPG For attachment to the dash, 8-32 press studs were installed in the inner flanges where they are also out of sight. The ribbed stainless was installed in the edge trim, then wrapped around our oxygen bottle to provide the radius. https://hosting.photobucket.com/imag...y/IMG_5555.JPG https://hosting.photobucket.com/imag...y/IMG_5556.JPG And a sneak peek at our trim fitted to the dash... https://youtu.be/wZk6FftVcC0 https://hosting.photobucket.com/imag...y/IMG_5558.JPG |
Re: 55 Wagon Progress
More shiny stuff...
https://hosting.photobucket.com/imag...y/IMG_5579.JPG https://hosting.photobucket.com/imag...y/IMG_5582.JPG https://hosting.photobucket.com/imag...y/IMG_5574.JPG https://hosting.photobucket.com/imag...y/IMG_5575.JPG Since I was on a road trip Sunday, I popped in and visited the patent display that we made the hood for. The owner has it re-wired and reflectors installed. This video gives a better idea of what it was used for.. https://www.youtube.com/watch?v=sw0gYxvY2m4 Back in the early 20's there were lights that would attach to the bumper and a cable driven mechanism attached to the front steering so that the light would follow the direction of travel. Advantageous for the limited brightness of the headlamps in those days. So this was likely a salesman's prop for selling such a lighting accessory. |
Re: 55 Wagon Progress
Before we could install the rear bumper we needed to install the rear bumper seal, this keeps exhaust fumes from sneaking through and getting sucked in the back tailgate. The seal sits in a channel which is then "crimped" with some rounded pliers. Only my rounded pliers did not work, we needed parallel jaw pliers. So these channel locks were modified by adding the round stock. Only that did not hold well enough, so a dimpler was added to the bottom jaw, as shown...
https://hosting.photobucket.com/imag...y/IMG_5624.JPG https://hosting.photobucket.com/imag...y/IMG_5622.JPG These dimples gave us enough grip, and any chips were removed and then recoated with a couple coats of epoxy primer. https://hosting.photobucket.com/imag...y/IMG_5623.JPG Here's the bumper added, and a video that better shows the hidden hardware... https://hosting.photobucket.com/imag...y/IMG_5712.JPG https://www.youtube.com/watch?v=XLtCAbLpv48 Here's a closer look at the forming of the edge trim for our dash inset trim. We had made a template out of 19 gauge steel to match the dash inset, and used it (and some heat) to form the point. This video shows the shrinking of the flange so the edge trim would match. The upper and lower edge trim was squeezed while applying heat to form a tuck for shrinking the flange and providing the radius. https://www.youtube.com/watch?v=Cwpt3_R4284 All shaped, before polishing.. https://hosting.photobucket.com/imag...y/IMG_5696.JPG Press studs installed... https://hosting.photobucket.com/imag...y/IMG_5720.JPG Ribbed stainless insert added and our green radius brake used to match the dash profile... https://hosting.photobucket.com/imag...y/IMG_5700.JPG One last touch-up to the polishing and installed in the dash..... https://www.youtube.com/watch?v=WpRCFd29c8Y |
Re: 55 Wagon Progress
Looking O so good Robert..!!!!!!
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Re: 55 Wagon Progress
Thanks Greg!
I've been remiss in posting an update. We've been doing a bit of block sanding interior parts, and its just hard to make those pictures look like any semblance of progress. We pulled the front fenders back off, we had mocked them up in order to modify the upper fender mounts at the cowl. They came with some excessively sized holes to allow plenty of adjustment, and we had filled in the factory hole and re-drilled to a normal clearance hole. Here shown after a spray of Organic Green KBC, and the stainless washers we used as shims. Hard to leave those stacked washers after we did the other cleanup in resizing the bracket's mounting hole. https://hosting.photobucket.com/imag...y/IMG_5826.JPG We had some black delrin scraps left over from making the radius arm bushings for Jared's 39, so we put them to use here. Since they had already been drilled, we added an aluminum plug and match drilled the holes to match the bracket. Installed, the black delrin is barely noticeable and makes for a cleaner detail over the stacked washers. https://hosting.photobucket.com/imag...y/IMG_5823.JPG https://hosting.photobucket.com/imag...y/IMG_5825.JPG https://hosting.photobucket.com/imag...y/IMG_5824.JPG Some of the parts we sprayed while the front fenders were off. https://hosting.photobucket.com/imag...y/IMG_5795.JPG https://hosting.photobucket.com/imag...y/IMG_5794.JPG https://hosting.photobucket.com/imag...y/IMG_5793.JPG https://hosting.photobucket.com/imag...y/IMG_5789.JPG https://hosting.photobucket.com/imag...y/IMG_5791.JPG With the core support reinstalled, we started on the installation of the inner fenders. https://hosting.photobucket.com/imag...y/IMG_5829.JPG Since our cowl bracket was all cleaned up now, we needed to address the attaching hardware. This started with 400 grit and worked up to 5000 trizact before hitting the buffer... https://youtube.com/shorts/nEgXyGHNFto?feature=share https://hosting.photobucket.com/imag...y/IMG_5831.JPG Much better! And so we can finalize the wiring at the back of the car, the tail-light housings had been sprayed in epoxy and we added some catalyzed white to the inner portion for some brighter lights. https://hosting.photobucket.com/imag...y/IMG_5864.JPG https://hosting.photobucket.com/imag...y/IMG_5866.JPG .....and the day job has me building anchored support stanchions for some phone lockers and naturally the mounting holes are on the back side for a wall mounting only. What we need are some bolting plates to hold things down as I wasn’t comfortable with rivnuts in the chinesium steel flange on the bottom. https://hosting.photobucket.com/imag...y/IMG_5835.JPG Well, said flange also has a 1/4” upward fold for added strength, so our bolting plate will need a tight reverse bend to offset those but still leave room for press nuts on the end flanges. https://hosting.photobucket.com/imag...y/IMG_5857.JPG So some 1/2” wide female VEE dies were set up opposing each other with just enough offset to make two bends at once. https://hosting.photobucket.com/imag...y/IMG_5854.JPG https://hosting.photobucket.com/imag...y/IMG_5853.JPG https://hosting.photobucket.com/imag...y/IMG_5850.JPG Shroud added for weather resistance.. https://hosting.photobucket.com/imag...y/IMG_5843.JPG |
Re: 55 Wagon Progress
Fantastic work Robert
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Re: 55 Wagon Progress
Thanks!!
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Re: 55 Wagon Progress
Last bit of progress, we got the hinges painted so hopefully we can get the tailgate installed this weekend...
https://hosting.photobucket.com/imag...y/IMG_5917.JPG installing more shiny stuff.... https://hosting.photobucket.com/imag...y/IMG_5967.JPG https://hosting.photobucket.com/imag...y/IMG_5966.JPG https://hosting.photobucket.com/imag...y/IMG_5968.JPG https://hosting.photobucket.com/imag...y/IMG_5970.JPG We had not pre-drill the holes for the partial spear on the doors when we installed new door skins, so here we mask off the bottom of the door and drill SLOWLY to prevent heat buildup. https://hosting.photobucket.com/imag...y/IMG_5973.JPG https://hosting.photobucket.com/imag...y/IMG_5972.JPG Then the fresh holes are touched up with two coats of epoxy primer. Once dry the spears are added.. https://hosting.photobucket.com/imag...y/IMG_5978.JPG And our dash clock showed up so we can get that hole filled as well |
Re: 55 Wagon Progress
While assembling the door bits, we noticed that the retaining clip for the reproduction lock cylinders did not match the originals, which would leave us with a gaping hole in the back side of the inner door.
https://hosting.photobucket.com/imag...y/IMG_6046.JPG https://hosting.photobucket.com/imag...y/IMG_6033.JPG So we had media blasted the originals and sent to the Shop at Shorty's for a cerakote finish of gun metal grey. As my luck would have it, the door skins we had installed had some accuracy issues in the lock hole locations. https://hosting.photobucket.com/imag...y/IMG_6035.JPG Aligning the clip to the lock hole would result in a slight misalignment out back... and you know Robert's not having that. https://hosting.photobucket.com/imag...y/IMG_6037.JPG With Cerakote still fresh, some trimming was done so we could use the original clips to fill the hole void, and the new ones would be used to hold the lock cylinder in place as well as the original clip, whose new job has been reduced to filling a slotted opening. Some window sealant will slow any movement of the pretend clip. https://hosting.photobucket.com/imag...y/IMG_6042.JPG https://hosting.photobucket.com/imag...y/IMG_6039.JPG https://hosting.photobucket.com/imag...y/IMG_6040.JPG https://hosting.photobucket.com/imag...y/IMG_6043.JPG https://hosting.photobucket.com/imag...y/IMG_6044.JPG And the same effort repeated for the driver's side. Where it wasn't as far off as the other side, our mods were still required. https://hosting.photobucket.com/imag...y/IMG_6052.JPG Mandatory Kramer photo bomb https://hosting.photobucket.com/imag...y/IMG_6053.JPG Adding the pull rod for the door lock.... https://hosting.photobucket.com/imag...y/IMG_6056.JPG and the addition of a rubber grommet will help keep rattles down. https://hosting.photobucket.com/imag...y/IMG_6057.JPG Jared applied some Kilmat inside the tailgate and we added more bling.. https://hosting.photobucket.com/imag...y/IMG_6054.JPG And we've had a casualty with the Baileigh magnetic brake. The magnet stopped working and some troubleshooting found an open with the coil. Some inspection of the supply wires found an over heat issue. Removing all the epoxy showed it's been warm for awhile.... https://hosting.photobucket.com/imag...y/IMG_6025.JPG https://hosting.photobucket.com/imag...y/IMG_6026.JPG https://hosting.photobucket.com/imag...y/IMG_6027.JPG https://hosting.photobucket.com/imag...y/IMG_6028.JPG So it looks like we'll be in search of replacement parts. |
Re: 55 Wagon Progress
Nice work on the "Robert ain't having it" issues..!!!!
I always wondered how your mag brake worked.. or I guess dont work now...but I know you'll getter done.. |
Re: 55 Wagon Progress
Thanks Greg!
More progress, we were test fitting the power antenna an noticed that the mounting bezel did not sit horizontally on the fender. I had quickly whipped up a wedge shaped and tapered spacer out of some aluminum as a quick test. https://hosting.photobucket.com/imag...y/IMG_6058.JPG Where that was functional, it did not match the chrome finish of the bezel. I picked up a chunk of 1" stainless rod (local drop cut) to make a duplicate out of stainless. The wedge shape was added first, using the 12" disc sander... then clamped in the Southbend for the taper cut and a hole boring. https://hosting.photobucket.com/imag...y/IMG_6148.JPG https://hosting.photobucket.com/imag...y/IMG_6153.JPG ....and trimmed off to length https://hosting.photobucket.com/imag...y/IMG_6154.JPG https://hosting.photobucket.com/imag...y/IMG_6156.JPG In order to hold this oddball shape for polishing, some rivnuts were used on a 1/2-13 bolt, with the wedge angle added to one for a more positive hold.. https://hosting.photobucket.com/imag...y/IMG_6158.JPG Completed, this matches the chrome finish of the bezel much better... https://hosting.photobucket.com/imag...y/IMG_6159.JPG https://hosting.photobucket.com/imag...y/IMG_6161.JPG Since we were ready to re-install the front fenders, I thought I'd grab pictures of our fine-tuning adjustment screws for the fender to door alignment. The hex bolt shown on the right is filling an existing hole that used to have a rubber plug in it. I guess having pulled out the dried and cracked old rubber plug, I wanted a more permanent solution. We were going to use that hole but it did not align with the rib on the fender's rear brace. So another hole was drilled next to it, a 3/8-16 AVK style rivet nut installed, and a fully threaded bolt added. The bolt head was covered with a rubber cap and the inside end of the bolt had a slot added for adjustment purposes. Now we could use a screwdriver to adjust the screw outward, pushing the center of the fender until it aligns to the door surface.. A jam nut on the inside tightens against the rivnut to prevent any movement. https://hosting.photobucket.com/imag...y/IMG_6176.JPG https://hosting.photobucket.com/imag...y/IMG_6177.JPG https://hosting.photobucket.com/imag...y/IMG_6184.JPG https://hosting.photobucket.com/imag...y/IMG_6178.JPG https://hosting.photobucket.com/imag...y/IMG_6183.JPG And with our upper fender mounts painted, they get installed using polished button head hardware and our barely noticeable shims we had fabricated. https://hosting.photobucket.com/imag...y/IMG_6186.JPG In the tooling department, we needed a tight radius reverse bend on some .090 aluminum, so a Gene Winfield inspired 1-1/4" round stock was added to our 4" pipe. This was bolted straight into tapped holes and used two stacked flat washers to provide the gap. The aluminum was 5052 alloy and was annealed prior to bending. https://hosting.photobucket.com/imag...y/IMG_6095.JPG https://hosting.photobucket.com/imag...y/IMG_6097.JPG https://hosting.photobucket.com/imag...y/IMG_6096.JPG |
Re: 55 Wagon Progress
More progress on the wagon. While reassembling the front end, Jared noticed the fenders were a bit high at the cowl. This next picture shows it, although the perspective makes it a bit exaggerated.
https://hosting.photobucket.com/imag...y/IMG_6186.JPG So we pulled each of our new shims we had made and shaved another 1/16" off the height. This shows the fender height after adjusting the shim height. https://hosting.photobucket.com/imag...y/IMG_6237.JPG But shows our next back up and punt moment. The wedge shim we had made for the antenna was too steep, and this shows the actual angle needed. So we made another with less angle... https://hosting.photobucket.com/imag...y/IMG_6238.JPG Note some "pre-polishing" was done on the lathe prior to cutting off the wedge to make things a bit easier. Final version installed and vertical orientation verified... https://hosting.photobucket.com/imag...y/IMG_6286.JPG https://hosting.photobucket.com/imag...y/IMG_6289.JPG Next, we got the driver's door wiring routed through the upper door hinge... much easier after the trial-and-error practice we did on the passenger side. https://hosting.photobucket.com/imag...y/IMG_6292.JPG ...and with the front fenders back on to stay, Jared reassembled some of the core support parts. https://hosting.photobucket.com/imag...y/IMG_6290.JPG Moving to the rear of the car, we started the rear tail-light install now that they have been painted inside and out. Wiring was routed through OEM style boots to help minimize any water intrusion into the lamp sockets. Replacement button contacts were used in the sockets (w-crimp) to eliminate any unneeded splicing of the wiring. Wiring complete, with bulb seal attached to the housing: https://hosting.photobucket.com/imag...y/IMG_6295.JPG https://hosting.photobucket.com/imag...y/IMG_6296.JPG Rivet-nuts were installed for mounting the housing.... https://hosting.photobucket.com/imag...y/IMG_6297.JPG https://hosting.photobucket.com/imag...y/IMG_6298.JPG Nice snug fit to the body, and a functional test to make sure we're done here.. https://hosting.photobucket.com/imag...y/IMG_6300.JPG https://hosting.photobucket.com/imag...y/IMG_6299.JPG Moving to the passenger side, we'd need to secure the harness to the tail-light swing arm mechanism (part of the hidden gas door mod) so we planned to add some heli-coils in the arm for adel clamps. I had a long 1/8" bit to get in close to the corner, but our final size of 13/64 for the 10-32 heli-coil tap would be another issue. https://hosting.photobucket.com/imag...y/IMG_6307.JPG Then I noticed some tubing in the scrap pile that had a 3/16 ID, just undersized. So our drill bit was clamped in the 3 jaw chuck of the lathe, and the tail stock used to press the two together. https://hosting.photobucket.com/imag...y/IMG_6302.JPG Now we had an extended bit to complete the heli-coil installation. https://hosting.photobucket.com/imag...y/IMG_6306.JPG https://hosting.photobucket.com/imag...y/IMG_6308.JPG https://hosting.photobucket.com/imag...y/IMG_6309.JPG ...and a functional test of the wiring on the arm... https://www.youtube.com/shorts/JzA6W2BdyyQ |
Re: 55 Wagon Progress
Wagon 2.0 progress, I was tasked with adding a paint job to this:
https://hosting.photobucket.com/imag...y/IMG_6190.jpg but had a couple of issues to address first prior to paint. The dropped axle design lacked lateral strength of an I-beam, so we ordered some 1/8 x 1/2 flat bar to cap the top and bottom, adding much needed strength. Next, the frame hoop was produced with limited tooling availability, and the corners made use of pie-cuts that some still remained and would show through the paint. I attempted to weld some of these closed, but realized it would be quicker to remake the hoop. https://hosting.photobucket.com/imag...y/IMG_6193.JPG Always one to make tools into multiple use, the new tubing corners were bent on our buffer stand "radius brake" https://www.youtube.com/watch?v=8oyTLqpeXSk https://hosting.photobucket.com/imag...y/IMG_6203.JPG https://hosting.photobucket.com/imag...y/IMG_6206.JPG https://hosting.photobucket.com/imag...y/IMG_6208.JPG https://hosting.photobucket.com/imag...psmLydbWcF.JPG The rear "axle" stanchions had been bolted on using rivnuts, but I was worried the side wall of the tubing may deflect from weight in the wagon. So in true Robert overbuilding form, some threaded standoffs were turned into a sleeve that would weld on both sides of the tubing for less stress upset. https://hosting.photobucket.com/imag...y/IMG_6244.JPG https://hosting.photobucket.com/imag...y/IMG_6245.JPG https://hosting.photobucket.com/imag...y/IMG_6247.JPG Both ends were ground flush prior to welding.. https://hosting.photobucket.com/imag...y/IMG_6248.JPG Welding the front end to the new frame hoop... https://hosting.photobucket.com/imag...y/IMG_6252.JPG Next, to clean up the front end components a bit in order to add oilite bushings... https://hosting.photobucket.com/imag...y/IMG_6253.JPG https://hosting.photobucket.com/imag...y/IMG_6256.JPG https://hosting.photobucket.com/imag...y/IMG_6257.JPG https://hosting.photobucket.com/imag...BHjfT2JCFT.JPG https://hosting.photobucket.com/imag...aU2jWY2uRQ.JPG https://hosting.photobucket.com/imag...y/IMG_6262.JPG https://hosting.photobucket.com/imag...y/IMG_6267.JPG With spindle perches welded to the ends of our "I-beam" front end... a test fit of all the bits.. https://hosting.photobucket.com/imag...y/IMG_6268.JPG And here with our center link added, the last fabrication detail needed will be the handle.. to be continued... https://www.youtube.com/watch?v=eE6G7vHhYmc |
Re: 55 Wagon Progress
Here's the hidden fuel door in action, and why we needed the helicoils for adel clamps to hold the wiring in place....and away from moving parts.
https://www.youtube.com/shorts/UwCy8mKRJFU The back end is starting to look like a car again... https://hosting.photobucket.com/imag...y/IMG_6366.JPG ....and more work on the other wagon, here's the start of the pull handle... https://www.youtube.com/shorts/a-8Nmkh_bmQ A functional test of the steering bits... https://www.youtube.com/watch?v=bGSptHK1WBc For the pull handle, we had tried out some knurling on aluminum to see if we liked that.... https://hosting.photobucket.com/imag...y/IMG_6346.JPG But this would have required more hardware, and the aluminum handle was over-ruled for simplicity of a welded steel tube. Here we formed the handle's hoop, and some side "extensions" were added so we could have a consistent shoulder around the "steering column" for fillet weld. https://hosting.photobucket.com/imag...y/IMG_6368.JPG https://hosting.photobucket.com/imag...y/IMG_6370.JPG https://hosting.photobucket.com/imag...y/IMG_6371.JPG https://hosting.photobucket.com/imag...GEjxt3UBcF.JPG And some shots in da weeds... may have clearance issues https://hosting.photobucket.com/imag...Ttav9RohUZ.JPG https://hosting.photobucket.com/imag...oAJuW7qBma.JPG |
Re: 55 Wagon Progress
Man that's a cool little wagon! Even though I was checking in for the 55 I'm still impressed.
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Re: 55 Wagon Progress
man i love that taillight gas filler..thats just freaking cool..!!!!!
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Re: 55 Wagon Progress
Sweet wagon...Jim
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Re: 55 Wagon Progress
Thanks guys!!
Some additional parts for painting, we had media blasted the door latch and tailgate latch pull rods, as well as the end clips. The rods didn't have much option for securing for paint, so we opted for some rare earth magnets screwed to the paint stand. We'd paint one side, let it flash, rotate 180*, and spray the other side. That's our plan... https://hosting.photobucket.com/imag...y/IMG_6430.JPG https://hosting.photobucket.com/imag...y/IMG_6433.JPG Jared had made a hoop holder for the end clips so they wouldn't get lost in the media blast cabinet, and it looked like a good holder for painting as well. https://hosting.photobucket.com/imag...y/IMG_6434.JPG We also needed to paint the steering column, so it was disassembled and media blasted to prep for epoxy primer.. To support the column on the paint stand some eyebolts were fabricated to fit the 1/4-28 threads. https://hosting.photobucket.com/imag...y/IMG_6437.JPG https://hosting.photobucket.com/imag...y/IMG_6438.JPG I missed getting pics after primer, so we'll get those next time.. Progress for our other wagon, the bead detail at the bottom of the wagon pan has some flat spots (defects) from the factory. As we will be spraying kandy paint, those spots need to be corrected so they won't be visible. https://hosting.photobucket.com/imag...y/IMG_6419.JPG https://hosting.photobucket.com/imag...y/IMG_6418.JPG So we made a set of dies for the Lennox to be able to give a consistent bead around the entire perimeter.. https://hosting.photobucket.com/imag...y/IMG_6420.JPG https://youtu.be/5sTsOj_Bqd8 much better: https://hosting.photobucket.com/imag...y/IMG_6425.JPG https://hosting.photobucket.com/imag...y/IMG_6426.JPG more to come... |
Re: 55 Wagon Progress
I'm not contributing a lot to your thread but I'm definitely following along and enjoy seeing the updates and creativity. Thanks for sharing and being so detailed in posts.
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Re: 55 Wagon Progress
Thanks Joe!
A few months back we had received some newly polished stainless spears (side trim) for the 55 wagon. Part of the payment was to fabricate a "factory delete" plate for the spare tire well of a 55 chevy in gasser form. He wanted to mimic the factory X pattern that is located along the centerline of the trunk. We recently got this done, and with as-installed pictures received, it seems a good time to post this as well. We had tried a sample using the bead roller, and also had made a die set for the Lennox that would produce both sides at once. Neither worked well at all. I didn't care for the bead roller version much at all since we would be relying on self guiding and the possibility of line deviation. So we opted for a set of offset dies that I had for the Lennox, and producing each side individually. The Lennox works well because the linear slide lets us clamp the part and produce multiple parallel embossings with good accuracy. https://hosting.photobucket.com/imag...y/IMG_6335.JPG A corking tool made from delrin was used to dress up the ends https://hosting.photobucket.com/imag...y/IMG_6338.JPG As primed by the owner... Yes, that is Wisconsin farmland. https://hosting.photobucket.com/imag...y/IMG_1248.JPG https://hosting.photobucket.com/imag...y/IMG_1249.JPG Installed... https://hosting.photobucket.com/imag...y/IMG_1257.JPG https://hosting.photobucket.com/imag...y/IMG_1256.JPG So there you have it, a rare OEM spare tire delete plate. |
Re: 55 Wagon Progress
Robert, nice job on the "rare OEM spare tire delete plate"...Jim
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Re: 55 Wagon Progress
Thanks Jim!
The boss lady had picked up a vintage three-shelved stand a while back, and we had been tripping over the parts in the media blast cabinet. https://hosting.photobucket.com/imag...6xG4EnZer7.JPG https://hosting.photobucket.com/imag...aV2NNuErFy.JPG https://hosting.photobucket.com/imag...y/IMG_4173.JPG After media blasting they were sent off to The Shop at Shorty's for a powder coat finish. He had some pastel green in stock so we went with that. Here's the preview picture he sent: https://hosting.photobucket.com/imag...ZrN3tf6T41.JPG We will get the parts picked up this week. We already ordered new stainless hardware in slotted screws and square nuts for the assembly. Next, the casters seemed in good condition but needed a refinish as well. So the OEM rivets were drilled out so the metal housing could get a Cerakote treatment in gun metal grey. In order to reassemble without rivets we made some faux rivets that will make use of 1/4-20 threads and sleeve retainer loctite to keep things together. https://hosting.photobucket.com/imag...y/IMG_6531.JPG https://hosting.photobucket.com/imag...ZBvUDQJKKs.JPG https://hosting.photobucket.com/imag...Ww36C71AFu.JPG A tap handle in the vise was used to clamp the "rivet" while it was threaded.. https://hosting.photobucket.com/imag...2UrJg55rJ1.JPG https://hosting.photobucket.com/imag...PA7JfqDiSn.JPG https://hosting.photobucket.com/imag...y/IMG_6546.JPG The nuts were rounded as well, leaving just enough flat for assembly, to mimic the rounded head rivet as well. Threads trimmed to size and the parts were then polished. https://hosting.photobucket.com/imag...y/IMG_6547.JPG https://hosting.photobucket.com/imag...y/IMG_6534.JPG https://hosting.photobucket.com/imag...y/IMG_6533.JPG |
Re: 55 Wagon Progress
We picked up the powder coated parts from The Shop at Shorty's, for reassembly we had ordered some replacement slotted oval head screws and square nuts in stainless so we could polish them up a bit for a bit of bling.
https://hosting.photobucket.com/imag...ZrN3tf6T41.JPG https://hosting.photobucket.com/imag...8yrgGog6Lz.JPG And no job is complete without undergoing the close scrutiny of the quality control inspector... https://hosting.photobucket.com/imag...y/IMG_6590.JPG https://hosting.photobucket.com/imag...hHcqLAhN1Z.JPG https://hosting.photobucket.com/imag...hoMJocgkp6.JPG |
Re: 55 Wagon Progress
Steering column one step closer to green paint...
https://hosting.photobucket.com/imag...y/IMG_6461.JPG and blocked to 500 grit... https://hosting.photobucket.com/imag...y/IMG_6500.JPG Working on removing dings and refining scratches on the windshield trim in prep for polishing. These pieces are less receptive to using the DA due to all the creases, so we've resorted to wet/dry paper up to 2500 and then polish. https://hosting.photobucket.com/imag...RMxVSUcLao.JPG https://hosting.photobucket.com/imag...4U2DQvE2Rr.JPG Jared getting the hang of this stainless work.... https://hosting.photobucket.com/imag...S4TiUREUyp.JPG For the other wagon, we went with a powder coat chrome finish to dress up that front dropped axle. https://hosting.photobucket.com/imag...K57pXppNeC.JPG And this is the second round of three coats of epoxy and blocking. Think this will be the last round, and then on to some silver base and blue kandy.. https://hosting.photobucket.com/imag...fA9f55j4WA.JPG |
Re: 55 Wagon Progress
Wow that's a big ol cat....is it a Maine coon?
Rolling shelf turned out really nice..!!! |
Re: 55 Wagon Progress
We thought he was, as did the rescue we got him from because that's how he was advertised. But the boss lady had his DNA tested and he is actually a Norwegian Forest cat. He's about 17-18 lbs, pretty solid.
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Re: 55 Wagon Progress
More work on the wagons. Jared and I continuing to repair some stainless trim. I was asked about our process, so here's a bit more detailed approach. But understand we are complete novices at this, so take any of this with a grain of salt.
To start, some light scuffing in line with 1500 grit helps to highlight any rock dings in the windshield trim.. https://hosting.photobucket.com/imag...RMxVSUcLao.JPG Once any defects are identified, they are LIGHTLY tapped outward from the back side to bring the defect outward where it can be removed. Then 400 grit is used to remove the defect (and by default some of the adjacent material). So we want the defect to be pronounced outward, but not too much. Better to tap it outward in repeated steps than to go too far and create a stretch. I missed getting a picture before we started on this "rock chip"; this was after a few passes with 400 on the 3M board (just above arrow).. It was tapped outward about 4 different times until we got it where the defect was sanded out. https://hosting.photobucket.com/imag...qnMezs6hEd.JPG Back side that was tapped.... https://hosting.photobucket.com/imag...8AzLJbxdUG.JPG https://hosting.photobucket.com/imag...t2bjkpEkaK.JPG https://www.youtube.com/shorts/BdSQMh6MOTU After removing all the dings, the surface was sanded working progressively through grits 1200, 1500, 2000, 2500, and then on to 3000 and 5000 trizact discs on the DA. Afterwards it was polished out on the buffer... https://hosting.photobucket.com/imag...zgMrdM7Q8H.JPG https://hosting.photobucket.com/imag...3St1Ca2kXP.JPG Some parts painted green so we can continue with more assembly... https://hosting.photobucket.com/imag...y/IMG_6631.JPG https://hosting.photobucket.com/imag...xAYZPRTc32.JPG https://hosting.photobucket.com/imag...dSSfJE4ovJ.JPG https://hosting.photobucket.com/imag...FJzpL4FMVx.JPG When we had mocked up the wagon frame we just had a 1/2” bolt stuck through the bottom of the pull handle. Now that we’ve got the frame back from chrome powder coating, it’s time for some final details. The bolt for the bottom of the pull handle needs to be an Allen bolt to match our kingpins, and we need one from each side to be symmetrical. A little late to thread any holes in the pivot piece, so we’ll go with docking hardware. A 1/2-13 bolt was turned down for 1/4-20 threads, and the opposite one drilled and tapped. https://hosting.photobucket.com/imag...ggmdow4hVE.JPG An allen wrench in the vise holds the bolt for threading https://hosting.photobucket.com/imag...n3VLCnoLuY.JPG https://hosting.photobucket.com/imag...6RvF3Psegx.JPG Bolt for the opposite side... https://hosting.photobucket.com/imag...j57aaviMa2.JPG https://hosting.photobucket.com/imag...dyNdZ1WCtP.JPG https://hosting.photobucket.com/imag...VwHdR574zn.JPG https://hosting.photobucket.com/imag...tnEanFLYWL.JPG https://hosting.photobucket.com/imag...K6s6UGa63r.JPG Frame is all done but trimming the axles, now to finish blocking the epoxy on the tub. https://hosting.photobucket.com/imag...y/IMG_6657.JPG |
Re: 55 Wagon Progress
Still block sanding the wagon tub.. Back to our stainless trim, we need to modify the upper door trim to hold our peep mirrors. We opted for the old school look of the peep mirrors but did not want to use the clamp on paint chippers. The front edge of the trim uses a machine screw through the door and into a nut plate. Our plans are to use a formed hole in the trim and use the hole in the door to attach the mirrors.
https://hosting.photobucket.com/imag...ZWRUyhUmsi.JPG https://hosting.photobucket.com/imag...MAkGeHjUwa.JPG As we had used the tail stock of the South Bend before with success, we made some press dies to match the mirror's stepped end and provide a flange in the holes for added strength. https://hosting.photobucket.com/imag...1nMLX7EYEU.JPG https://youtu.be/sFO7CYYbC9U https://hosting.photobucket.com/imag...y/IMG_6718.JPG https://hosting.photobucket.com/imag...y/IMG_6719.JPG https://hosting.photobucket.com/imag...y/IMG_6720.JPG https://hosting.photobucket.com/imag...y/IMG_6721.JPG https://hosting.photobucket.com/imag...y/IMG_6722.JPG Trial test of the mirror, yellow rag hung outside the rear window for a more visible reflection https://hosting.photobucket.com/imag...y/IMG_6724.JPG https://hosting.photobucket.com/imag...y/IMG_6725.JPG |
Re: 55 Wagon Progress
Some more fabrication work for the day job, we had a door seal that was being abraded by a non-skid strip on the threshold, and wanted to drop it down some as well for better clearance. So a new threshold was made from 16 Gauge #4 brushed stainless. Where the old used countersunk holes for the #8 screws, we opted for the more correct version of dimpled holes. Provides more contact area for better seated hardware.
https://hosting.photobucket.com/imag...12qr6b4xWD.JPG Dies were made for the dimpling process, they used a 1/4" shank just pushed into a drilled hole in some bar stock vs. welding together. This will allow quick changeout for other sizes/shapes of dies for use in the press brake. https://hosting.photobucket.com/imag...GqB2j9nDrn.JPG https://hosting.photobucket.com/imag...y/IMG_6740.JPG https://youtu.be/FafzVr8eTPM https://hosting.photobucket.com/imag...dRB2KkRW1c.JPG Next, to gain a bit more clearance for the door seal, the new threshold was located and the protrusions of the rubber flooring were scored with a utility knife at the threshold edge. Next, we used a multi-tool to shave down these protrusions that would be beneath the threshold. This wasn't much, but better than what was there before. https://hosting.photobucket.com/imag...X6bnbk78hw.JPG https://hosting.photobucket.com/imag...hF1J97xnaT.JPG https://hosting.photobucket.com/imag...y/IMG_6755.JPG Back on wagon duty, we've been continuing on stainless polishing. We had been doing some of the shorter sections by sanding on top of my 4 wheel shop stool as it has a nice flat top surface. https://hosting.photobucket.com/imag...MjcGCbYTpj.JPG Once we got to the longer sections of trim, this became too cumbersome, so some 1/2" MDF was repurposed as a "holding fixture" while we refined the damaged scratches and dings. A Black Diamond longboard was used with 500 grit PSA paper to highlight any low spots, high spots, or other carnage. Then some LIGHT DUTY metal bumping to address the issues and a repeat of the highlighting sanding. Once all the defects were addressed, we then worked progressively through 600, 1200, 1500, 2000, and 2500 w/d paper. Then 3000 and 5000 Trizact, and finally on to the buffer. https://youtu.be/THKxgvIdVZw A modification of our "fixture" to hold the curved end of the trim... https://hosting.photobucket.com/imag...y/IMG_6761.JPG https://youtu.be/N5cgoFXjCDk https://youtube.com/shorts/tViITsStf_A?feature=share https://youtube.com/shorts/zYWU_zc4q1w?feature=share Jared helps out here to help stabilize the skinny trim and keep it from flopping around. Once quick mis-step at this point is about an hour minimum of recovery. https://youtu.be/Q0h6FuKog44 Nice reflection of the door opener in the ceiling after buffing... https://hosting.photobucket.com/imag...utvphsHctj.JPG trim clips added... https://hosting.photobucket.com/imag...5HRWhjnfmg.JPG https://hosting.photobucket.com/imag...y/IMG_6781.JPG ...and our driver's mirror added... https://hosting.photobucket.com/imag...njAc117h3Q.JPG https://hosting.photobucket.com/imag...NQ7tsJHr86.JPG |
Re: 55 Wagon Progress
Friday night was paint night. We started with a coat of SPI epoxy thinned for sealing, then two coats of Galaxy gray shimrin basecoat, then 4 coats of Cobalt Blue Kandy, and two coats of SPI universal clear.
https://hosting.photobucket.com/imag...y/IMG_6807.JPG https://hosting.photobucket.com/imag...eghSaF7ufg.JPG First coat of Kandy: https://hosting.photobucket.com/imag...kMdoKXkSnq.JPG It was loosely assembled Saturday morning and carried into the sunlight for pictures. The low morning sun was not enough to wake up the metallic in the basecoat, and this looks jet black. https://hosting.photobucket.com/imag...HHt85js544.JPG A bit later, it’s starting to wake up the blue…. https://youtu.be/SeT3ykEg_wA After wagon assembly and photo op, we did some more Stainless scratch refinement... Two long pieces left to go. and one on order. Dana had taken one somewhere for straightening, and the results left us with a wrinkle and a crack forming. So that one's replacement is on the way from The Stainless Shoppe. https://hosting.photobucket.com/imag...DnRjiVWZAd.JPG https://hosting.photobucket.com/imag...y/IMG_6673.JPG Jared putting the eagle eye on the remaining stainless to find any defects... https://hosting.photobucket.com/imag...boZkijZUB7.JPG Reassembling the steering column after painting... some heat shrink was added to the harness to help prevent abrading against the steering shaft. Our steering wheel puller kit did not have the needed parts for compressing the spring for the ts cam/horn ring, so we made a push ring and modified some 5/16 bolts for the cause. Much cheaper than grinding on the snap on parts. https://hosting.photobucket.com/imag...y/IMG_6831.JPG https://hosting.photobucket.com/imag...y/IMG_6830.JPG https://hosting.photobucket.com/imag...LnAhY5QZaw.JPG https://hosting.photobucket.com/imag...GC3QKmys4m.JPG https://hosting.photobucket.com/imag...FsRLb6T281.JPG Sunday morning we loaded up the wagon for it's maiden voyage, a shakedown run at Eddie's Brunch and Car Show, located at Bailey's Olde Breton Inn. This isn't a real large show (although it grows every year) but it's one of those must attends, and all the proceeds benefit our local Hospice. Some takeaways on the wagon design, the pull handle length that was designed for a small child inside the wagon was too short for a 6' tall fella with a long stride. Felt like yap dogs at my heels… And I think the frame design may need air bags, where it did well on the pavement, there was quite a bit of drag (rolling resistance) with the grass up in the frame. https://hosting.photobucket.com/imag...y/IMG_6979.jpg https://hosting.photobucket.com/imag...y/IMG_6980.jpg https://hosting.photobucket.com/imag...y/IMG_6982.jpg https://hosting.photobucket.com/imag...y/IMG_6983.jpg https://hosting.photobucket.com/imag...y/IMG_6976.jpg https://hosting.photobucket.com/imag...y/IMG_6977.jpg *Car show pictures borrowed from FB |
Re: 55 Wagon Progress
wagon turned out great!!
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Re: 55 Wagon Progress
Thanks Greg! Still have it scheduled for striping and lettering by Hotrod Jen, so it should be totally finished in a couple weeks.
Jesse Harris, a metalshaper local to me, did a recent video on using the TIG for performing spot welds. He was kind enough to send me the video so we could share it with others... https://youtu.be/JRBcLeRjN3Q |
Re: 55 Wagon Progress
thats a cool idea, but i bet it wont work with mine..my tig is a lift arc setup
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