|
Re: 55 Wagon Progress
More installing stainless trim. The screw holes for the beltline trim that wraps into the tailgate opening had been filled when we shaved the lead seams. So we used some tape to protect the paint as we aligned the side trim to the lift gate trim before drilling the holes.
https://hosting.photobucket.com/imag...jPpH5xUZnN.JPG https://hosting.photobucket.com/imag...DzeZsL3fpR.JPG https://hosting.photobucket.com/imag...y/IMG_7020.JPG https://hosting.photobucket.com/imag...y/IMG_7087.JPG One piece to go on the left side, awaiting the trip from WI. https://hosting.photobucket.com/imag...y/IMG_7088.JPG Next, we attempted to install our vent windows in the "reconditioned" frames the owner had bought. Only we noticed they weren't so ready for installation... https://hosting.photobucket.com/imag...Gy1Zso9hQt.JPG and bent... https://hosting.photobucket.com/imag...JcK6Kh5fhN.JPG Well, since we're on a roll, lets check the stainless trim that divides the vent and side windows. This had been "reconditioned" and included with the bent and cracked vent frame. Looks like they just polished up the dents and scratches. Not going to meet our standards. https://www.youtube.com/watch?v=ToR2iF0sNeQ So we media blasted the original frames, which had no damage, and dropped them off at the Shop at Shorty's for a Cerakote finish. https://hosting.photobucket.com/imag...y/IMG_7108.JPG Inspecting the stainless trim, we found the originals to be less beat up than the reconditioned stuff, so we opted to straighten out the originals. Here's a comparison of the trim, the two on the left are the reconditioned that had been polished right over the defects. The two on the right are the originals, the left of the two has had any dings/dents pushed from the back in prep for our refinement process. (except the one up top I missed) The right one has gone through our w/d 360, 600, 1200, 1500, 2000, and 2500, all done wet. There are some minor scratches still, so we'll go through this process once more prior to buffing to make sure we have a flawless finish. https://www.youtube.com/watch?v=UIQcvWRF9nU And a helpful hint for those who dabble in polishing stainless. We've all had occasion where the stainless slips off the buffing wheel, bouncing off the buffer shaft, causing another 2-3 hours to correct. We added a rubber grommet to cover the nut and a plastic end cap to cover the threads. Less chance of damage from those mis-steps. https://hosting.photobucket.com/imag...bkY8ekoPS1.JPG https://hosting.photobucket.com/imag...RfPAKar4Xq.JPG We did get some more chrome on the front. Look, no bolts!! https://hosting.photobucket.com/imag...ihjnKRu6CE.JPG https://hosting.photobucket.com/imag...TXswnAV1TG.JPG |
Re: 55 Wagon Progress
Wow
|
Re: 55 Wagon Progress
Very nice ...!!!!!!
|
Re: 55 Wagon Progress
Thanks Greg!!
More progress on the wagon, working on the parts so we can assemble and install the vent windows. For our glass installation, we did things twice as the 1/16 rubber did not give a snug enough fit. So here is our second round using 3/32 thick rubber. One inch wide strips were cut out of the sheet and lubricated with an Ivory/water mix. https://hosting.photobucket.com/imag...eVPEeD1jbT.JPG https://hosting.photobucket.com/imag...Xg7wEbJvzW.JPG The rubber was wrapped around the glass and it was pressed down inside the frame by hand. Then a "slight" squeeze of the frame to ensure it wasn't sprung open from the installation process. https://hosting.photobucket.com/imag...dwjmtJPuKh.JPG These got moved to the attic for a good heat baking (drying the soapy solution) and we'll trim the rubber flush with the chrome vent frame in a couple of days. Next, onto prepping the stainless trim for the vent windows for buffing, refining the scratches. Detail work like this is more difficult with parts flopping around in your hand, so some MDF was found the correct size (width) to hold the wide portion of the trim, and another piece of MDF was shaved to fit the narrow piece of trim. We should have these done this weekend. https://hosting.photobucket.com/imag...GdwnnH8Qmt.JPG https://hosting.photobucket.com/imag...y/IMG_7310.JPG https://youtube.com/shorts/aXjasXvwN...3weASGnXwPDeuK https://youtube.com/shorts/KaRW2OMmo...aHI9eAk13uNpS6 Next, we picked up our battery, but the lifting handle bosses on the ends of the battery interfered with our OEM hold down. https://hosting.photobucket.com/imag...YKQEDfFhS9.JPG https://hosting.photobucket.com/imag...Lb1Quo1Faq.JPG Not to be dissuaded, the belt file made short work of a shave. https://hosting.photobucket.com/imag...LQV5ig7Ttq.JPG Luckily the mount hides our sanding marks. Much better down where it belongs... https://hosting.photobucket.com/imag...4gSkfJqRer.JPG Like it's made to go there... https://hosting.photobucket.com/imag...y/IMG_7376.jpg |
Re: 55 Wagon Progress
Well in our typical back up and punt fashion, the original battery hold downs that we had already powder coated did not fit the battery, too short. So we ordered some round stock in stainless to fabricate some new ones.
https://hosting.photobucket.com/imag...FawSCxVyqR.JPG A threaded standoff was modified to provide an angled surface for using as a hammer form to get the bottom "hooks" consistent... https://hosting.photobucket.com/imag...y/IMG_7489.JPG https://hosting.photobucket.com/imag...X1GjqPPDyX.JPG All polished up... https://hosting.photobucket.com/imag...pmWZHVkmZd.JPG Installed, and no polish job is complete without addressing the ends of the rods.. https://hosting.photobucket.com/imag...y/IMG_7592.JPG https://hosting.photobucket.com/imag...y/IMG_7593.JPG Assembling our vent windows, the excess rubber is trimmed using a No. 11 scalpel blade for a nice and tidy fit https://hosting.photobucket.com/imag...y/IMG_7402.JPG https://hosting.photobucket.com/imag...y/IMG_7403.JPG All the bits assembled https://hosting.photobucket.com/imag...nRw5bfmgN9.JPG installed... https://hosting.photobucket.com/imag...y/IMG_7590.JPG https://hosting.photobucket.com/imag...y/IMG_7591.JPG And more stainless we missed, the parting bands for the front arm rests, complete with a form-fitted sanding/polishing fixture https://hosting.photobucket.com/imag...y/IMG_7404.JPG |
Re: 55 Wagon Progress
Trying to assemble the tailgate so we can put it on, but our latch actuator is absolutely worn out in the square hole, the handle just about rotates inside of it. They don't make repop's (that I'm aware of) and someone just offered a rebuilding service at over $300. So I reached out to my go to used parts outlet and a good used one is on the way, mailed the same day.. Reference photo:
https://hosting.photobucket.com/imag...y/IMG_8915.JPG So while we're waiting on parts to load up the rest of the bits on the tailgate, lets chase the threaded holes.... https://hosting.photobucket.com/imag...y/IMG_8911.JPG https://hosting.photobucket.com/imag...y/IMG_8912.JPG The console just got dropped off, we had some material in the corners that was pulling due to all the stretching that had taken place. In order to keep things more permanent, I came up with some 19 gauge stainless "trim lock". A hemmed edge helps keep from cutting into the upholstery. It gets clipped in place, shoved into the corner snugly, and through drilled for installing solid rivets. https://hosting.photobucket.com/imag...y/IMG_8925.JPG https://hosting.photobucket.com/imag...y/IMG_8918.JPG https://hosting.photobucket.com/imag...y/IMG_8922.JPG https://hosting.photobucket.com/imag...y/IMG_8919.JPG https://hosting.photobucket.com/imag...y/IMG_8923.JPG In order to match our dash insert, the console insert will also be oriented horizontally (lines left to right) https://hosting.photobucket.com/imag...y/IMG_5580.JPG https://hosting.photobucket.com/imag...y/IMG_8926.JPG We also got some of the stainless added to the front end. What an alignment pita. Still have some tweaks to do.. https://hosting.photobucket.com/imag...y/IMG_8877.JPG |
Re: 55 Wagon Progress
Incredible work. This will be one of those cars that you can just look at for hours and still not catch all of the fine details. Love following along with your progress. Thanks for sharing.
|
Re: 55 Wagon Progress
Thanks Joe! That's what we've strived for all along, subtle little changes to have people scratching their head... :lol:
|
Re: 55 Wagon Progress
Looking good Robert...Jim
|
Re: 55 Wagon Progress
Thanks Jim!
More console work, time to fabricate the hemmed surround for the insert. In order for the surround to be seamless, we need to do some welding. https://hosting.photobucket.com/imag...FJYqAJa4zd.JPG For our corners we relieve the flange and trim the back side to about half the hem width. This gives us less material in the tucks for shrinking in the corners. https://hosting.photobucket.com/imag...aR9SCfX1QU.JPG https://hosting.photobucket.com/imag...UWNAksfk3r.JPG We cut a fake insert out of 18 gauge CRS with rounded corners to use as a hammer form, gives us something to hammer against when we heat up the corners. https://hosting.photobucket.com/imag...4EuAnF7E2o.JPG https://hosting.photobucket.com/imag...)_IMG_8985.png Everything's a tool, and when the PVC pipe is the only thing in the shop that matches our needed radius, it's what we use for a radius bender. https://hosting.photobucket.com/imag...y/IMG_8989.JPG To prevent our hem from closing during the radius forming, some 18 gauge strips were placed in the hem. https://hosting.photobucket.com/imag...FbJdaaQoAG.JPG Press studs used to attach to the console and will be hidden underneath the center panel. https://hosting.photobucket.com/imag...FpeYwkCzkk.JPG Insert cut out to match our poster board sample, then it gets 800 grit, then 1000 through 5000 foam pads, then buffed.. https://hosting.photobucket.com/imag...YyRiVqPEat.JPG https://youtube.com/shorts/Wlbrs908h...H0gssNlu9xhBkm Then we cover it with frisk film to protect our buffed surface. https://hosting.photobucket.com/imag...XYLzReNz96.JPG https://hosting.photobucket.com/imag...yPoPeayAtX.JPG Test fit... https://hosting.photobucket.com/imag...1615GvpG4D.JPG Installing the surround to the filler panel https://hosting.photobucket.com/imag...y/IMG_9049.JPG Still have to touch up some areas with the buffer (heat from tacking the press studs) but here's the test fit. https://hosting.photobucket.com/imag...mW5YorYc5Z.JPG https://youtube.com/shorts/0FhzILNBY...Pzr-q_-0oYgu6S . |
Re: 55 Wagon Progress
Next step for the console, we need to cut some holes for the shifter. Using the Chevelle style horseshoe shifter, we don't have the factory style brush seals or trim bezel for the center plexi indicator. So lets see what we can come up with first to seal the shifters side arms. I didn't have any brush stock left over from the splice trailer, and window felt wasn't thick enough. But I did have some bulb seal that looked promising. To make a surround to hold the bulb seal, we used a folded piece of 16 gauge stainless, and put an offset to hide as much of the edge trim that holds the seal as possible.
https://hosting.photobucket.com/imag...y/IMG_9091.JPG https://hosting.photobucket.com/imag...y/IMG_9093.JPG https://hosting.photobucket.com/imag...y/IMG_9092.JPG To close off the ends, we used the linear stretch dies in the Lennox... https://youtube.com/shorts/cD1TrEwah...kBU5isw7LFb_dK https://youtube.com/shorts/--rTDf9M2...5Dk3opzAYzdQtD After welding the one end in place, the console was mocked up to get the overall length needed on the shifter seal. https://youtube.com/shorts/N9mJWH6Rj...w6PBdNXo32kGPq https://hosting.photobucket.com/imag...y/IMG_9132.JPG The top flanges will be trimmed to the same width as our polished stainless edge trim surround on the console insert. This one will be used for the passenger side arm, the drivers side will have a wider flange toward the driver to accommodate the shift selector position marking. |
Re: 55 Wagon Progress
Very nice Robert..!!!...
|
Re: 55 Wagon Progress
Amazing Progress. :metal::metal:
|
Re: 55 Wagon Progress
Thanks guys! the stretching dies used on the ends took the metal from 16 gauge (.059) to .031 thickness.
|
Re: 55 Wagon Progress
We had ordered a 4 position switch for the power windows in the wagon, with plans to install in the console. Not knowing the origin of the part when it showed up, I thought some due diligence was in order and broke out the multimeter to test all the switch positions for connectivity. Wouldn't you know, one of the end switches had no contact in one position. Further investigation showed that the spring contact board was held in place with four tabs from the factory, except we only had three, which allowed the board/switch to lose contact. I sent the next picture of the damaged part (pointing to the damage with a white wire) in a message to the eBay seller who immediately questioned my abilities with a multimeter and assured me it functioned exactly as it should.
https://hosting.photobucket.com/imag...y/IMG_9278.JPG So for a more direct approach, I assured them I knew how to operate a multimeter, and perhaps they should look at the attached picture this time. To help eliminate any interpretation errors, I had doctored the original rear view picture to make things more obvious since they missed the visual cues the first time.... https://hosting.photobucket.com/imag...KgbJQcJRsB.JPG Oh, that. We'll send out a new switch. Thank you.. So with the console on hold to make sure we didn't have to use a different style switch (in case their whole batch was bad) we turned our attention to the tailgate, and started the fit up of the Mad Mooks polished stainless border trim. https://madmooks.com/ To preface, I will say the Mad Mooks parts are some of the nicest fit and finish parts you'll find ANYWHERE to trim out your Tri-five Chevy, as well as parts for other GM vehicles. Only the corner pieces didn't fit our tailgate. It appears that when yours truly did the rust repairs of the tailgate (before repop's were available) the replacement patches weren't exactly spot on. So yes, this is my F-up.. https://hosting.photobucket.com/imag...y/IMG_9201.JPG https://hosting.photobucket.com/imag...y/IMG_9388.JPG We had also ordered some stainless strips for the voids in the tailgate from McMillan Rod and Custom and wanted to retain the stainless border to use with these parts. https://hosting.photobucket.com/imag...7RGwysBao5.JPG https://hosting.photobucket.com/imag...cterVrb3WH.JPG We had some 19 gauge stainless in stock, so let's give this a go. First order is to make sure we can duplicate the dimpled hole for the countersunk screws... https://hosting.photobucket.com/imag...y/IMG_9208.JPG https://hosting.photobucket.com/imag...y/IMG_9197.JPG Next, the folded (side) flange on the trim piece is a consistent width and will need to be real accurate. So we opted for a hammer form to match the shape, used a tipping die to thin the bend location (to tell the metal where to bend) and a backstop on the Lennox to set the flange height. A paper pattern was used to capture the tailgate outline. https://hosting.photobucket.com/imag...bX4KKVHkEd.JPG https://hosting.photobucket.com/imag...y/IMG_9292.JPG https://hosting.photobucket.com/imag...b9fRgCj45W.JPG https://hosting.photobucket.com/imag...AJR9QhqKRC.JPG After the flange had been folded, the top part of the hammer form is set aside and the bottom section used to hold the part for polishing. We'll get it polished, trim the width and punch dimple holes, and then do a final polish. https://hosting.photobucket.com/imag...3FTHjMGj5v.JPG https://hosting.photobucket.com/imag...y/IMG_9384.JPG https://hosting.photobucket.com/imag...y/IMG_9385.JPG Test fit looks much better to match our one-off tailgate. https://hosting.photobucket.com/imag...y/IMG_9390.JPG https://hosting.photobucket.com/imag...y/IMG_9391.JPG https://hosting.photobucket.com/imag...7n1pbRsDTf.JPG |
Re: 55 Wagon Progress
We got the other side trim done for the tailgate and I had been asked to show the hammer form in more detail, so here's another go.. We actually started by pulling a paper pattern of the profile, some autobody masking paper is taped to hang over the edge, and the tracing done to show where to trim. Although we didn't have the plastic in the way at the time, here the pattern is after trimming.
https://hosting.photobucket.com/imag...an3wLbJoQk.JPG This is the pattern we use for the overall of the stainless, so that once the flange has been folded we will have a border of paint surrounding the trim (set in somewhat). Once the 19 gauge stainless has been trimmed to match our pattern, we use the tipping die in the Lennox to thin the "bend line", this gives the metal a suggestion of where it needs to bend so we should have a somewhat sharper crease given how the MDF tends to compress under a hammer blow. Where I would normally use one of our round backstops on the lower die, this shows to leave us without contact with the backstop at the initial entry and final exit from the machine, as the backstop is centered on the die. To correct that, we opted for 3/4 flat stock that gives us contact the entire width of the die set. https://hosting.photobucket.com/imag...y/IMG_9429.JPG The backstop distance sets the height of the side flange of the trim, and here is the stainless after running through the tipping die for thinning the bend line. https://hosting.photobucket.com/imag...y/IMG_9428.JPG https://hosting.photobucket.com/imag...y/IMG_9427.JPG Then the stainless is clamped between our MDF hammer form, note the outer portion of the hammer form matches the thinned bend line exactly. https://hosting.photobucket.com/imag...y/IMG_9435.JPG https://hosting.photobucket.com/imag...y/IMG_9436.JPG https://hosting.photobucket.com/imag...y/IMG_9432.JPG The Sandwich is held together with screws and then clamped in the vise for the hammering operation... https://youtube.com/shorts/5WiGK0550...bhT7Mo5BjpPIHR Once complete the bottom half of the hammer form becomes a stable base for pre-polishing, and some shorter screws are used to keep thing in unison. We use our typical polishing sequence of 400, 800, 1500, and then polishing on the buffer using green compound for a darker hue. https://youtu.be/3OGAjPCnGwQ?si=cryFGWW1Q2eeEVfL After the initial polish, the outer flange is covered with masking tape (to protect from scratching at this next step) and calipers are used to set the width and mark the cut line, like shown here.. https://hosting.photobucket.com/imag...y/IMG_9384.JPG The bulk is trimmed away using our Milwaukee M18 shears, and final done using Wurth snips. The edge is fine tuned with our Dynabrade belt file, and then the holes are located and dimple countersunk. Then another polish job, and all the parts are located in prep for drilling the screw holes into the tailgate. Really happy with the nice parallel setback from the edge with these new trim pieces to match my patch panels. https://hosting.photobucket.com/imag...CPCnuBJwW1.JPG https://hosting.photobucket.com/imag...7Pr2SqwoKb.JPG https://hosting.photobucket.com/imag...HJxkp9xr74.JPG Next we'll get all the holes drilled and our upholstery added in the center... |
| All times are GMT -4. The time now is 08:11 PM. |
Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.
Copyright 1997-2022 67-72chevytrucks.com