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Re: 55 Wagon Progress
Very nice work, love to watch a real pro do this type of repair.
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Re: 55 Wagon Progress
Had a couple hours this evening so I decided to remove some mud daubers nest....
http://i5.photobucket.com/albums/y16...Picture251.jpg http://i5.photobucket.com/albums/y16...Picture252.jpg http://i5.photobucket.com/albums/y16...Picture254.jpg Used a combination of burr grinder, roloc sander, etc, to clean out the rust and scale as best I could. Once the car is up on the rotisserie again, the troublesome voids such as these will get a good flood of paint. http://i5.photobucket.com/albums/y16...Picture256.jpg As this one needs a bit more flange turned in, the inside will need a bit more stretch to go with it. A suitable hammer with more heft will come in handy. http://i5.photobucket.com/albums/y16...Picture258.jpg http://i5.photobucket.com/albums/y16...Picture259.jpg http://i5.photobucket.com/albums/y16...Picture260.jpg A couple fitments and adjustments, and this is ready for the welder... http://i5.photobucket.com/albums/y16...Picture261.jpg http://i5.photobucket.com/albums/y16...Picture262.jpg http://i5.photobucket.com/albums/y16...Picture263.jpg http://i5.photobucket.com/albums/y16...Picture264.jpg and with it getting late, we'll cover the welding on the next update.. |
Re: 55 Wagon Progress
Time to finish this part up....
http://i5.photobucket.com/albums/y16...Picture263.jpg http://i5.photobucket.com/albums/y16...Picture266.jpg http://i5.photobucket.com/albums/y16...Picture267.jpg All cleaned up.... http://i5.photobucket.com/albums/y16...Picture275.jpg |
Re: 55 Wagon Progress
Starting on the tailpan, we were torn on using the pinch weld flanges. Some of the "subtle" mods we had done included removing the pinch weld flanges and leaded seam above and below the tail lights to get rid of a dirt trap/rust generator...
http://i5.photobucket.com/albums/y16...Picture276.jpg http://i5.photobucket.com/albums/y16...Picture277.jpg The pinch weld seam for the tail pan is also in the tires path, especially given the wider rear tires and mini-tubs it's now using. http://i5.photobucket.com/albums/y16...Picture278.jpg So we decided to get rid of these as well, and butt weld the panel in. With the car still sitting on the frame, the standard offset snips had some interference issue with the frame rails... http://i5.photobucket.com/albums/y16...Picture281.jpg Luckily my lovely bride had picked these up for me a couple years ago... http://i5.photobucket.com/albums/y16...Picture282.jpg For a much better fit in such a tight area... http://i5.photobucket.com/albums/y16...Picture283.jpg http://i5.photobucket.com/albums/y16...Picture284.jpg The tailpan was trimmed as well, leaving a bit extra to insure we had enough metal to span the gap... http://i5.photobucket.com/albums/y16...Picture288.jpg Used the tipping tool to unfold the remainder of the flange and the door skin hammer to flatten it out... http://i5.photobucket.com/albums/y16...Picture289.jpg http://i5.photobucket.com/albums/y16...Picture290.jpg After another test fit, the reproduction showed to be not that accurate, go figure.... http://i5.photobucket.com/albums/y16...Picture296.jpg After marking the new bend location, the bead roller was fitted with the tipping die to relocate the bend... http://i5.photobucket.com/albums/y16...Picture301.jpg Now that the tipping die has left a crease indicator on the bottom side, a hammer and anvil is used to flatten out the incorrect crease... http://i5.photobucket.com/albums/y16...Picture303.jpg http://i5.photobucket.com/albums/y16...Picture304.jpg For a much better fit..... http://i5.photobucket.com/albums/y16...Picture307.jpg http://i5.photobucket.com/albums/y16...Picture308.jpg With tail gate test fitted.... http://i5.photobucket.com/albums/y16...Picture295.jpg Well that's about all for this go round, will start welding the tail pan in next time... |
Re: 55 Wagon Progress
The tail pan and rear opening were prepped a couple days ago by painting some epoxy on the surfaces that would be adjacent to each other after welding for some rust prevention. Tonight holes were added to the tail pan for plug welding, and the panel fitted up..
http://i5.photobucket.com/albums/y16...Picture311.jpg http://i5.photobucket.com/albums/y16...Picture312.jpg Here's the epoxy, I use a letter A size (.234) drill bit for my plug welds, and to clean the epoxy from the adjacent panel, I use a letter A that has been flattened and backfaced to form a cutter similar to an end mill. It cleans the paint well, and hardly touches the metal on the adjacent panel.. http://i5.photobucket.com/albums/y16...Picture314.jpg http://i5.photobucket.com/albums/y16...Picture315.jpg http://i5.photobucket.com/albums/y16...Picture316.jpg http://i5.photobucket.com/albums/y16...Picture318.jpg http://i5.photobucket.com/albums/y16...Picture321.jpg Butt welding the vertical seams... http://i5.photobucket.com/albums/y16...Picture319.jpg http://i5.photobucket.com/albums/y16...Picture320.jpg http://i5.photobucket.com/albums/y16...Picture322.jpg http://i5.photobucket.com/albums/y16...Picture323.jpg Note the views from the back side show full penetration welds. Next, grinding the welds in prep for the next set of weld dots.. http://i5.photobucket.com/albums/y16...Picture325.jpg http://i5.photobucket.com/albums/y16...Picture326.jpg |
Re: 55 Wagon Progress
....and finishing the vertical welds...
http://i5.photobucket.com/albums/y16...Picture328.jpg http://i5.photobucket.com/albums/y16...Picture329.jpg http://i5.photobucket.com/albums/y16...Picture331.jpg http://i5.photobucket.com/albums/y16...Picture332.jpg http://i5.photobucket.com/albums/y16...Picture333.jpg |
Re: 55 Wagon Progress
Thought I'd spend some time this evening to see how I could clean up these corners....
http://i5.photobucket.com/albums/y16...Picture331.jpg Trimming out some of the excess... http://i5.photobucket.com/albums/y16...Picture334.jpg http://i5.photobucket.com/albums/y16...Picture335.jpg Used the roll former die to make the radius.... http://i5.photobucket.com/albums/y16...Picture337.jpg http://i5.photobucket.com/albums/y16...Picture338.jpg http://i5.photobucket.com/albums/y16...Picture339.jpg Fitted, welded, and looking much better! http://i5.photobucket.com/albums/y16...Picture340.jpg http://i5.photobucket.com/albums/y16...Picture342.jpg http://i5.photobucket.com/albums/y16...Picture343.jpg http://i5.photobucket.com/albums/y16...Picture344.jpg http://i5.photobucket.com/albums/y16...Picture345.jpg http://i5.photobucket.com/albums/y16...Picture346.jpg http://i5.photobucket.com/albums/y16...Picture347.jpg |
Re: 55 Wagon Progress
COOL! I didn't know you were over here, I've been a big fan on the GJ.
I have to tell you, you've been an inspiration. To do the level of work you do, and yet make it look so do-able combined with the willingness to show dummies like me is a gift to all in the community. Now that you're here, I'll have to take my stuff down! LOL The s-box thread is inspired by you, in some way, please check it out! Yes, and laugh, but I'm trying! Thanks again, glad you're here. |
Re: 55 Wagon Progress
Thanks, glad to hear my posts have helped. Nice work on the s-box, most would consider something like that a disposable car, but you're getting it back to being dependable transportation. And as you've shown at the very least it is a good platform to hone your skills for the next project. Experience, along with the determination to try and improve your methods with each challenge, will go far in developing those skills. You've done well!
Moving on to the right side of the wagon..... http://i5.photobucket.com/albums/y16...Picture348.jpg Trimming the excess for the radius piece to fit in.... http://i5.photobucket.com/albums/y16...Picture350.jpg http://i5.photobucket.com/albums/y16...Picture351.jpg Trimmed to fit.... http://i5.photobucket.com/albums/y16...Picture352.jpg Welded in place... http://i5.photobucket.com/albums/y16...Picture353.jpg Welds dressed http://i5.photobucket.com/albums/y16...Picture354.jpg Yeah, I like this look much better! http://i5.photobucket.com/albums/y16...Picture355.jpg |
Re: 55 Wagon Progress
Robert, what are you using to grind welds in the tight areas?
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Re: 55 Wagon Progress
Where I normally use a 1/16" cutoff wheel to knock down the proud of the weld, this corner is much too tight for that. So the majority of the weld was removed with a carbide burr in the die grinder, then switched to a 3/4" dia 80 grit sanding drum on the die grinder.
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Re: 55 Wagon Progress
Quote:
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Re: 55 Wagon Progress
My local hardware store carries the sanding drums, but they seemed to last about 5 revolutions. My welding supplier just ordered me in bulk quantity of them (Nortons in 3/4 and 1-1/2 dia) in various grits, they seem to last a bit longer than the blister packs at the hardware store, but still wear out sooner than you'd expect. At least the bulk qty got me a better price...
Not too much shop time this weekend, but I did manage to test fit the tailgate to see how well it matched the new radiuses added to the opening. http://i5.photobucket.com/albums/y16...Picture356.jpg http://i5.photobucket.com/albums/y16...Picture357.jpg There are a couple areas the gaps will need tweaking, but the "new" corners should help add to the other subtle changes. |
Re: 55 Wagon Progress
Wanted to say thanks- I used the "make a pass of tacks, then grind off with the wheel, then make a pass, then grind" method tonight- worked great! Much better, and faster grinding! Another tool in the box! Thanks again.
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Re: 55 Wagon Progress
Been a busy couple weeks working on honey do's, painted the inside of the garage so I could hang a canoe for storage, so I could paint the inside of the car trailer that it used to be stored in, so we could sell the car trailer. Late today, found a bit of time for the wagon, working on some of the plug welds for the rear valance....
http://i5.photobucket.com/albums/y16...Picture355.jpg The ones at the bottom attach to two braces underneath, and fitted the tailgate to pull in the valance to match the bottom of the tailgate... http://i5.photobucket.com/albums/y16...Picture358.jpg http://i5.photobucket.com/albums/y16...Picture359.jpg http://i5.photobucket.com/albums/y16...Picture360.jpg http://i5.photobucket.com/albums/y16...Picture361.jpg |
Re: 55 Wagon Progress
Looks good! You must have a patient customer, with work that nice, I'd be losin' it to see it finished!
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Re: 55 Wagon Progress
I'm ready to see it finished myself! :lol:
Worked today to finish up the weld seam on the passenger quarter panel. First, I wanted a profile template to check the crown of the panel. As the rear half of the driver's quarter was NOS, this would make a good template.... http://i5.photobucket.com/albums/y16...Picture362.jpg http://i5.photobucket.com/albums/y16...Picture364.jpg http://i5.photobucket.com/albums/y16...Picture365.jpg http://i5.photobucket.com/albums/y16...Picture366.jpg Adding an alignment mark to the quarter.... http://i5.photobucket.com/albums/y16...Picture367.jpg http://i5.photobucket.com/albums/y16...Picture368.jpg http://i5.photobucket.com/albums/y16...Picture369.jpg Using the profile template against the welded seam of the passenger side, we can see the low area along the center. This is a typical problem with using "half quarters", welding through the center of panel tends to flatten out this low crown area. A full quarter with the welded seam up top where there is a bit more crown tends to not have as much of a "flattening" effect. http://i5.photobucket.com/albums/y16...Picture370.jpg http://i5.photobucket.com/albums/y16...Picture371.jpg Finishing the welds and checking with the profile template..... http://i5.photobucket.com/albums/y16...Picture372.jpg http://i5.photobucket.com/albums/y16...Picture374.jpg Still shows some more crown needed through the middle of the panel, will do some more planishing tomorrow... http://i5.photobucket.com/albums/y16...Picture373.jpg |
Re: 55 Wagon Progress
Nice work :metal: Thanks for sharing ;) Nate
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Re: 55 Wagon Progress
See, this is just the thing I gotta see... I'm fixin' to do something similiar soon. How do you planish when you have VERY limited to nothing for rear access for on-dollying? Thanks for all you show us, I gotta get a shrinker/stretcher.
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Re: 55 Wagon Progress
Awesome work for sure thanks for sharing.. I have a question on the spot weld drill bit you made? How did you make that? What do you feel the benefits of it are? So all in all I guess its a few questions.. Thanks..
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Re: 55 Wagon Progress
I read a restoration publication quite a few years back where they did a comparative test of the long term benefits of epoxy primer and weld through primers. They concluded that epoxy offered better long term protection against rust re-occuring, and I have been using epoxy ever since. Granted, either one will give better protection than none at all, so I don't think one could find too much fault with using either.
I have been using the epoxy primer, and any panels that are overlapped, pinch welded, etc together, I like applying EP at a minimum to the areas between the panels being welded and also areas that are inaccessible later (like inside rockers). I usually will prep the outer (or more accessible for welding) panel with plug weld holes, and use a modified drill bit the same size as the plug weld holes to clean out the bottom of the hole on the adjacent panel. The modified bit is made by flattening and backfacing using a 3" roloc sander, making it look similar to a milling bit. I think I used a 120 grit disc. Because of the flat, it tends not to cut into the metal but does a good job of cleaning off the paint in prep for welding the panels together. http://i5.photobucket.com/albums/y16...ion/pic003.jpg http://i5.photobucket.com/albums/y16...c/cb76db16.jpg http://i5.photobucket.com/albums/y16...c/146d4d8e.jpg I think one thing to keep in mind using either of the two primers, be sure to observe the cure time for maximum resistance to the heat from welding. |
Re: 55 Wagon Progress
Next on the list for the wagon, the upper gate. It has a similar stance as the lower gate when closed, and as such, water lays along the inner window frame at the bottom.
http://i5.photobucket.com/albums/y16...Picture375.jpg http://i5.photobucket.com/albums/y16...Picture376.jpg Ice pick test.... http://i5.photobucket.com/albums/y16...Picture378.jpg The lower bend is fairly flat, going to a tipped flange in the form of an arc, the inside has some compound curves going to the window opening flange... http://i5.photobucket.com/albums/y16...Picture379.jpg http://i5.photobucket.com/albums/y16...Picture380.jpg http://i5.photobucket.com/albums/y16...Picture381.jpg http://i5.photobucket.com/albums/y16...Picture382.jpg I'll get this bottom cut out next week and attempt to form it in one piece, flange to flange, for a easier job of replacing.. |
Re: 55 Wagon Progress
Can't wait!
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Re: 55 Wagon Progress
Incredible work Robert! Would love to come watch you work, and learn more from a master. Thanks for all the detailed info. :metal:
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