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06-22-2014 07:52 PM S10 fabrication (cont'd)
Finished the passenger side A-pillar today. Here's the piece I fabricated next to the cardboard pattern I made to start. Welded the piece in, merging the windshield frame to the door jamb. I am really pleased with the welding improvement after fixing the mig gun. I have been dreading all of these welds unnecessarily. Hundreds of tacks executed today with very few burn-throughs, almost all with good penetration. I am stoked!


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  [Entry #100]

06-21-2014 09:52 PM S10 fabrication (cont'd)
Finished nibbling on the three pieces I need to put together to finish the A-pillar. Seven hours of trimming and fitting, fitting and trimming. Finally have the pieces tacked together. All the time I worked on this, I thought about the giant presses GM has to mash pieces like this out of flat sheet metal every second. And GM's fit better, too.


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  [Entry #99]

06-15-2014 08:50 PM S10 fabrication (cont'd)
The door skin from the extra Malibu door has a nice curve to the sheet metal that works well for the pieces I need to finish the bottom of the A pillar.

I used the cardboard pattern to cut a couple of pieces from the door skin. A while back I made some small anvils from some pipe elbows. I used one to roll the edge in the side piece; the edge will meet match to the windshield frame. I also used a dolly to form a 90 degree edge that will form the gap with the door edge. I also used the English wheel to crease the portion of the piece that will cover the gap between the windshield frame and the fender.


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  [Entry #98]

06-09-2014 09:04 PM S10 fabrication (cont'd)
Started working on the intersection of the A-pillar, the fender and the door with some Cheerios cardboard and blue tape.


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  [Entry #97]

06-01-2014 08:49 PM S10 fabrication (cont'd)
Capped the open ends of the roll at the top of the firewall. Finished the curved ends for the cowl cover. I am really pleased with the result. I guess a year invested trying to get this right was time well spent.


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  [Entry #96]

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