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Re: 55 Wagon Progress
Thanks for the generosity of your time to share these methods. Awesome!
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Re: 55 Wagon Progress
Bomp, still learning myself :lol:
Was in the middle of media blasting the innards of the lift gate and noticed the threads for these nut plates didn't look too "full" A test with a 10-24 screw showed that some of the holes were so bad that they had a "slip" fit. http://i5.photobucket.com/albums/y16...Picture453.jpg These hold the rubber bumpers on the bottom inside edge of the lift gate. The spot welds are drilled to release the nut plate.. http://i5.photobucket.com/albums/y16...Picture454.jpg http://i5.photobucket.com/albums/y16...Picture455.jpg The new ones are cut out of some 10ga steel, holes drilled and tapped. http://i5.photobucket.com/albums/y16...Picture456.jpg yeah, these threads look much better.... http://i5.photobucket.com/albums/y16...Picture457.jpg Where I normally use a couple screws to hold nut plates in place for welding, with the close proximity of the plug weld hole the screw heads would obscure some of the hole, and we would undoubtedly be welding in the screw heads for difficult removal. For this case, we'll use some brass tubing as a spacer. Since the tubing I picked up passes though the screw holes, a sacrificial lock washer is used for it's minimal diameter. http://i5.photobucket.com/albums/y16...Picture459.jpg http://i5.photobucket.com/albums/y16...Picture460.jpg A dab of anti sieze is placed on the screw threads to insure they don't get welded in place from arcing across the threads.. Plug welded, and screws removed. http://i5.photobucket.com/albums/y16...Picture461.jpg Lock washers removed and plug welds ground flush.... http://i5.photobucket.com/albums/y16...Picture463.jpg http://i5.photobucket.com/albums/y16...Picture468.jpg And now we can finish up the media blasting.... http://i5.photobucket.com/albums/y16...Picture469.jpg http://i5.photobucket.com/albums/y16...Picture470.jpg |
Re: 55 Wagon Progress
And if all looks good after your super micro inspection it's time for some primer.
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Re: 55 Wagon Progress
Can you post more details on the cutoff wheels you use? Brand, where to get them, how much longer they last than a "standard" Norton one? Thanks!
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Re: 55 Wagon Progress
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You got it! All ready for some epoxy inside! Quote:
I think if you find ones rated for stainless steel, you'll find them to last longer and to put much less of a brown cloud in the air for you to breathe. I use these by Sait: http://i5.photobucket.com/albums/y16...Picture378.jpg I get them from my local welding supply, Three Mules Welding Supply. Your local welding supply or even online sources should be able to help out. Unsure of the time frame on how long they last, but I've sure slowed down in changing them out since using the stainless rated wheels. |
Re: 55 Wagon Progress
3M Green Corps 4" discs are the BOMB! NOT cheap, but they last like iron. Unless your dumb ass drops them off the bench onto the floor. I use 'em on my air cutoff wheel. I got some pretty good ones at .035 thk for the 4 1/2" electric, name escapes me.
Beeeutiful work, as always. |
Re: 55 Wagon Progress
Yeah, I think we all have done the drop, crack, cuss! :lol:
Had a couple hours to spend in the shop this evening, so I decided to mark out the roof for re-repairing. http://i5.photobucket.com/albums/y16...Picture471.jpg Then another line was dropped down about 1/4" to be used for the "rough cut". A cutoff wheel was used and then trimmed with the snips. The lower section was trimmed about 1/2" above the drip rail.. http://i5.photobucket.com/albums/y16...Picture472.jpg To start, a section was marked off just wider than my sheet metal pliers. Then the spot welds, which were visible from the top, were drilled. A cutoff wheel was used to grind through the end(s) of the section being removed. Then the sheet metal pliers used to rock the panel back and forth to break the spot welds loose. http://i5.photobucket.com/albums/y16...Picture473.jpg http://i5.photobucket.com/albums/y16...Picture475.jpg http://i5.photobucket.com/albums/y16...Picture477.jpg Got about half of it removed, we'll save the rest for later so I can get some primer on the inside of some of the lift gate parts and the roof skin patch. http://i5.photobucket.com/albums/y16...Picture478.jpg http://i5.photobucket.com/albums/y16...Picture479.jpg http://i5.photobucket.com/albums/y16...Picture480.jpg http://i5.photobucket.com/albums/y16...Picture481.jpg http://i5.photobucket.com/albums/y16...Picture482.jpg |
Re: 55 Wagon Progress
Continuing with the dissecting of the roof.....
http://i5.photobucket.com/albums/y16...Picture483.jpg When I got into the section with the old roof, it was difficult to see the spot welds (for drilling) down inside the drip rail. The underside was more accommodating, so the face of the drip rail was marked with the sharpie to use as a reference while drilling... http://i5.photobucket.com/albums/y16...Picture484.jpg The lower corners of the opening were trimmed to size so that the roof patch could be clamped down into the drip rail. This will help to get more accurate markings on the roof skin for trimming the rest of the opening. http://i5.photobucket.com/albums/y16...Picture489.jpg http://i5.photobucket.com/albums/y16...Picture488.jpg C-Clamp vise grips added to secure the overlapped panels for marking, then a straightedge used to read the crown of the roof to insure there were no dips or puckers along the top of the joint.... http://i5.photobucket.com/albums/y16...Picture490.jpg My favorite scribe, a local auction purchase... http://i5.photobucket.com/albums/y16...Picture491.jpg Scribing the roof panel http://i5.photobucket.com/albums/y16...Picture492.jpg Not much to spare! Trimmed the opening with some offset snips... http://i5.photobucket.com/albums/y16...Picture493.jpg http://i5.photobucket.com/albums/y16...Picture494.jpg Corners touched up with a 1-1/2" drum sander http://i5.photobucket.com/albums/y16...Picture495.jpg http://i5.photobucket.com/albums/y16...Picture498.jpg Clamped in place to hold the shape while we wait for the .023 ER70S-7 to come in. Note the butt weld clamps will be removed at welding for a tight fit-up. http://i5.photobucket.com/albums/y16...Picture496.jpg http://i5.photobucket.com/albums/y16...Picture497.jpg |
Re: 55 Wagon Progress
How many vise grips do you have.
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Re: 55 Wagon Progress
Somewhere around 75 pair... when you get welding you need clamps!
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Re: 55 Wagon Progress
BOMP pointed meto this thread… and I am in debt to him! Thank you very much for sharing your work, it is :jdp:
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Re: 55 Wagon Progress
Nice fitup!
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Re: 55 Wagon Progress
Thanks for the comments guys..
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Re: 55 Wagon Progress
Thank you for showing all the precision craftsmanship.
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Re: 55 Wagon Progress
MP&C. Nice job. Are you using a different nozzle on your mig gun?
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Re: 55 Wagon Progress
oops...double post
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Re: 55 Wagon Progress
The gun does have a screw in tip that is sized to the wire to keep it center, so I did change that out when I changed to the .023. Other than that, everything was the same...
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Re: 55 Wagon Progress
I understand the thread in tip is sized for 0.023 wire but what I meant was the outer nozzle. It looks like it has a step down in it like ones you can get for tig torches.
Thanks! |
Re: 55 Wagon Progress
It does have a step down feature, but that's the same and only nozzle that came with the machine over 20 years ago...
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Re: 55 Wagon Progress
Cool! Never seen one like that before. Now on to the hunt for spoolarc easy grind locally.
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Re: 55 Wagon Progress
If it's easier to find the -7, actually now that I've used the EZ grind, I prefer the -7. Both have nice flat welds, but the EZ tends to leave a patch of soot around the weld, and is more prone to splatter. I just think the -7 was cleaner. In planishing, comparing last night's roof repair to the earlier fender shaves using .035 -7 wire, to me the -7 appears to planish easier.. So if I had the choice, I would choose -7. If availability is an issue, either should be better than the harder welds of the -6 wire..
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Re: 55 Wagon Progress
Thanks! All I can find is the -6 stuff and that is what I'm using. 0.023. Suppliers all say "all we have is over there on the shelf".
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Re: 55 Wagon Progress
I've had to order mine, but if your supplier doesn't seem willing there's always online...
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Re: 55 Wagon Progress
Good to hear a straight comparison. I really liked the EZ grind, especially vs. -6. It takes a bit of adjustment!
I bought my 2# spool off Amazon. |
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