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04-25-2009 11:19 PM Horn Baffle V
It was a short day. I went back to the swap meet this morning. Bought a SKIL palm sander for $5. I think the deal of the meet was probably a 70 or 71 El Camino. A little rough, but the neighborhood nuisance sticker indicated the owner was eager to sell. Marked down from $350 to $325.

The second side always goes better than the first. I changed the angle of the cut from being parallel to the side to being perpendicular to the bottom. I also used the Dremel tool with the 409 cut-off wheel (actually went through 4 of them) to cut the horn recess. I find the 409 makes a perfect kerf for MIG welding sheet metal. So far it went together a lot easier than the other side. It should test fit and finish on Tuesday.


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  [Entry #194]

04-24-2009 09:57 PM Chin II - Horn Baffle IV
The usual drill. Add rosette weld holes. Weld through primer.

Then the chin was mocked up and the rosettes were put in.

After adding a couple of fillet welds along the side and end of the support, and a lot of grinding, the chin went back of a test fit.

It all fits. The supports must have move a little on welding. I am hoping a little persuasion with a hammer will loosen things up. If not, cut and move. I really don't want to do that.

The panel is in. Both the inner fender and the horn baffle still needs the triangle piece to fill the gap between the two angles. And some of the bolt holes will need opened up. But it is getting there. I will move to the right panel next. Hopefully I can get it done tomorrow.


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  [Entry #193]

04-24-2009 09:44 PM Making the Chin Fit
The swap meet was big. I was surprised how many vendors. Bought a fan. May go back tomorrow to see if any new stuff shows up on Saturday.

I decided I needed to get the chin to fit before I went on with the horn baffles. There are two support angles than attach to the radiator core support. These will have to be moved before the chin will fit.

The speed nut also needs to move 3/4". I decided the the best way to do it was to move the tab. A 3/4" section was cut out the the tab with the speed nut moved.


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  [Entry #192]

04-23-2009 10:46 PM Horn Baffle III
There were several times I thought it might make more sense to start with a flat piece of sheet and custom make a new piece.

Once it was cut and tacked together, the baffle was test fit to the car. I liked the way it started to come together.

There are still some places that need welds. I also have a lot of grinding to do. But I think when it is done, it will pull of the factory look. Time will tell.

Going to the Creek County swap meet tomorrow. And Saturday. If the wind doesn't kick up too bad, I will also have to paint the room that was lifted last year. Busy three day weekend!



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  [Entry #191]

04-23-2009 10:40 PM Horn Baffle II
After some measuring, it looked like the best plan of attack was to cut 3/4" out of the baffle up to the hump.

My first thought was to cut out the horn recess and replace it with a flat panel. After looking at it, I thought it might be easier to work the recess to maintain a more stock look. We shall see.

After the angle is cut off the baffle, a couple of templates were made to guide opening up the angle to fit the part correctly.

A lot of hammering and bending followed.


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  [Entry #190]

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