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  #46 (permalink)  
Old 11-01-2019, 11:25 PM
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Very nice. I am enjoying this, and staring at the pics until I understand them!

Its like watching "Weldsmoke" and the Marshal is closing in on the outlaw.

What a treat. Keep up the solid work.

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  #47 (permalink)  
Old 11-02-2019, 06:11 PM
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"Weldsmoke"... I like that! Thank You for the compliments, this has been "kind of" fun actually. It's a big mess and a pain the arse but it's been a while since I've done fab work like this. The last was on the van and this is just getting me pumped to get the body finished on that...

Got a good start on the passenger side today. Went through the same routine, removing dead metal from the firewall flange, as I did on the drivers side.

After a couple of hours of cutting and grinding... Same as the other side, the flange cleaned up very well so I will get good welds when I stick all of this together.

Cleaned out the lower A pillar pocket and got two patches fabbed up for that area. Went pretty smooth and the fit is really good.



I ran out of steam about 6:00pm, came in, took a shower and had some dinner. Got a lot done though and the rest of this wont take to long.
Won't get anything done tomorrow, going antiquing with some friends.
Thanks for following along!
Mark
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  #48 (permalink)  
Old 11-22-2019, 09:19 AM
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Getting this thread caught up to current progress.

Clecoed in.

Measuring and drawing up and laying out the lower panel.

Trimmed out and the firewall flange is bent up.

Both pieces Clecoed in. I still had to shape the break at the bottom of the firewall where it kicks back for the toe board. The hard parts are done though and I was getting pretty cold by this time...


It's gotten very cold here in Mi.
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  #49 (permalink)  
Old 11-22-2019, 09:21 AM
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Got a bit more done on the passenger side. Fitting the new panels in and getting the lower flange bent up.


What should I do with that old access panel? Leave it be and reattach with screws? Or just take it out and weld it up?


Been so dang cold I can only work for an hour or so. I need to prep and paint the cowl before I weld these patches in. Don't know when that will happen.
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  #50 (permalink)  
Old 11-22-2019, 09:24 AM
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All of the major patch panels are done. I need to drill and punch plug weld holes in the passenger cowl and pieces yet but I was not getting on the floor tonight.
Here is the last piece I made last night.

I developed the bends using a piece of cardstock cut to size.



Cutting out the replacement drain channel parts. I am doing this in two pieces per side rather then one just to ease getting everything welded in.
These are the tall covers that keep water coming off the upper cowl from splashing down on the fresh air vents. LH and RH.

These are the flat patterns for the actual channel that goes under the cover. One is left, one is right. I'll get these bent up tomorrow.

I modeled these up a week ago Monday... It was 9 degrees here, I was NOT going out to the shop...
Here are dimensioned drawings if you want to copy them.
The covers, 1 right, 1 left, mind the bend, this is the right hand side.

This is the flat pattern for the channels. Again there are two needed, 1 left and 1 right. This is the right side.

This is the right side bent up.

These are some screen shots of my computer models.


Mark
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  #51 (permalink)  
Old 11-22-2019, 09:26 AM
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I dug out the 3 in 1 Saturday morning and got the two channels bent up.


For a cheap HF bender this thing does a good job. I've been using it for 8 years and have not been disappointed with it...

Getting them bent the long way was the hard part. After some offhand cutting on the bandsaw I could get the them bent into the shape needed for the cowl.





There isn't much I can do to get these fit to the cowl until I get the patch panels welded in.
Passenger side.
[imghttps://media.fotki.com/2v2HofE2Fx9EDKg.jpg][/img]
Drivers side.

With the channel covers held in place. These should work!


Thanks for watching.
Mark
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  #52 (permalink)  
Old 11-22-2019, 09:27 AM
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I did fire the car up and move it outside while I did the bending. I really appreciate the TBI F.I. The car hadn't been started since August and she fired right up! I let her idle for about half an hour while I worked on the channels.


After Going in to warm up and have some lunch I hit it again. This time I was working on the warm side.
I pulled off all of the patch panels earlier and had them on the warm side. I punched the plug weld holes in the pass. side stuff, hit them all with a wire wheel and got some self-etching primer on them.
Drivers side parts.

Passenger side parts.

Primed and ready to go!


Now, to get the Astro chassis moved so I can get this car on the warm side...
Mark
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  #53 (permalink)  
Old 11-22-2019, 09:34 AM
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I am building a Pro-Touring Astro van chassis on the heated side of the shop. I had an issue with the hidden valve stems on the front wheels hitting the Vette calipers. To get the chassis movable I had to fix the problem.
I had a buddy weld up the old holes, and I drilled new ones outboard of the spokes so they would have no interference with the calipers.



Now to get the shop cleaned up and the wagon rolled over here.
This is where everything is at as of today.
Thanks for watching.
Mark
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  #54 (permalink)  
Old 11-23-2019, 06:03 PM
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Did a lot of cleaning and vehicle shuffling today. The wagon and Astro chassis have swapped places so I can get to work finishing the cowl tomorrow.
These pics are off my phone, sorry for their largosity...


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  #55 (permalink)  
Old 11-26-2019, 06:07 PM
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Got a bit done tonight. My wife helped pull the hood, she's had this duty a few times before so it went smoothly. I pulled the hinges and did some more clean up on the cowl. Found a bit more rust in the top of the cowl, buried under filler and bubbling like an unwatched pot... and about 10 more colors under the red...



More rust in the cowl...

Far OUT Man! Should I offer signed posters in a limited run?

Wire brushed and sprayed with converter.


With this done I hope to start welding in panels tomorrow!
Mark
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  #56 (permalink)  
Old 11-29-2019, 05:47 PM
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I've been picking away at the patch panels. I had some scrap leather I was "saving" for something. I used a couple of strips to protect the wiring and fuse box from the welding heat. Seemed to work fairly well. I did start a couple of small fires but I was keeping my eye on the interior AND I had a blowgun and the air hose already staged inside because I knew this would happen. No big deal, and I used the air gun to cool off the welds from the inside as I was doing them. Took me most of the day but going slow was a good thing.
The leather strips were from a Wassely chair I refurbished a couple of years ago.

Stuffed up into the top of the dash they covered all of the wiring and down to the floor.

With all of the panels in place.

That all happened Wednesday. I didn't get out to the shop yesterday. This morning I went out and hit all of the weld holes with a cartridge roll on the angle grinder.

Getting the welding started.


The welding went "okay". Had no issues where there was new steel. The old rusted steel was pretty thin and I had to go easy with very short trigger pulls on the gun. had to "build up" the thin steel to get it heavy enough to support the heat from a full spot weld pull.
Everything is pretty complete at this point. Still have two loose panels to put in but I needed to knock down the height on the welds a bit to get them to fit correctly.

Everything welded in and primed. Definetly not very pretty but it will do the job. Still need to fit the drain channels in but I was running out of steam by the time this was done.

Got a lot done today, won't get too much done tomorrow but Sunday should see the passenger side welded up and possibly the drain channels as well.
Thanks for looking.
Mark
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  #57 (permalink)  
Old 12-01-2019, 08:38 AM
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Got out to the shop early Saturday morning, didn't have much time as we were headed to the west side of the state for family stuff.
I got the drivers side drain channel fit up and screwed into place.

I was going to weld all of this in but right now I think I will just run a couple more screws into it and leave it at that. It's not structural so, doing it this way, will let me coat the entire flange with seam sealer, screw it down and then smooth out the transitions. No welding means the seam sealer will cover the whole flange so it will be fully sealed up.
I'll do the same with the big cover plate.

Once everthing is primed and the rest of the cowl seam sealed this will be a permanent fix. I will probably have to do some trimming to this anyway to get the outer cowl to slip over it but that will be easy if it is removable.
Mark
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  #58 (permalink)  
Old 12-01-2019, 07:39 PM
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I didn't get near as much done as I had hoped today. I started working on the drivers side outer cowl fit-up. It is pretty close but I need to get it snuggled up along the bottom of the firewall a bit more. I am having to tweak the original metal and the new tin along the top seam. I will be raising the original metal another 1/16th inch and lowering the new piece 1/16th to bring the whole cowl piece up about an 1/8th.
I also got a lot done on the other side but still have some work to do in prepping for the spot welding.
I was out there most of the morning, took a break for some lunch and ended up going with the wife to get groceries. Her folks are under 24/7 home care and my wife is the only one out of six siblings that can get the groceries... Anyway it's easier with the two of us so I went with her to do that.
Here are some pics of the progress.
Mostly fit up. The silver dots are where the plug weld holes will be punched.




[imghttps://media.fotki.com/2v2H3bSN8x9EDKg.jpg][/img]
Mark
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  #59 (permalink)  
Old 12-03-2019, 07:50 AM
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Looking good as new. Too bad all that artistry will be hidden behind the fender. Does someone made clear fenders ? ..
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  #60 (permalink)  
Old 12-04-2019, 08:29 PM
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Thanks for the atta boy TMP! I wouldn't call it art but it better then the nothing that was there!
I got a lot done the last couple days. Tuesday afternoon I got the passenger side all ready for welding. Did some re-fitting of the A pillar patches and got all of the plug weld holes punched and drilled. I also did some clean up in the interior and made sure the carpet was pulled back.
After some welding.

Just right of center you can see where I was chasing a burn thru. The original tin would just vaporize when I started the welding. I had to go very slow and use very quick, short trigger pulls to try and keep as much heat out of the material as I could until I built up a layer thick enough to handle a full pull. I would change the setting on the spot weld control from .1 second to about .3 second to slowly build the weld puddle. Most of the time I use a 1 second pull and that works fine on the new metal.

Most of the new metal welds look pretty good and I didn't have to fight the welder to get those done.
After a bit of grinder work and wire wheeling this is ready for etch primer.

I will do a bit more work down in the hinge pocket but the original steel down there is horrible to weld to. Going slow and cooling after every weld is working okay but it gets tiresome real quick...

It's getting there! Tomorrow I will get the pass side drain channel fit up and start prepping the outers to go on.
Mark
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