Surgery on the ol woody ! a little early tech stuff.

[Tinbender]

The woody project survived the first round of reconstructive surgery. The cowl is now "as one", and I've started on the rockers. After the rockers are in, the car goes home to be fit to the new frame, so it will be a while before I work on her again. Maybe then I'll have some time to catch up on my other projects http://www.jalopyjournal.com/ubbthreads/images/graemlins/smirk.gif

This first picture is the drivers side cowl innerstructure, before the cowl replacement. With what was left of the old cowl removed, I blasted the area, then treated some of the unaccessable areas with conversion coating. (I do use conversion coating, but only where I can't remove rust)

[Tinbender]

This shot showes the one of the patches on the rocker. This area will be covered, so I didn't spend alot of time making it pretty. (this car is going to be a driver, so the cost will be keep down when possible)

[Tinbender]

Next step was to set the new cowl back in place and line everything up. The bottom 6" of the replacement cowl was rotted away, so it had to be fabricated.

[Tinbender]

These are the parts I made to replace the missing section. They look a little crude, but hey, I'm still learning too http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Tinbender]

Before finish shapeing & welding in the parts, the cowl needed to be squared up. I took X measurements that showed almost 1/2" difference from side to side, then used a slip jack to pull the cowl into shape.

[Tinbender]

The jack.

[Tinbender]

A close up of the clamping to pull the cowl. Sometimes you have to get creative to get the movement you want, w/o doing additional damage.

[Tinbender]

Once I was happy with the fit, I tacked in the lower cowl parts. The parts had to be fitted many times, and the fender mocked up, but I'm going to skip some of the steps, otherwise I'd be here all day. I still have work in the shop to do! After the parts were tacked on, I pulled the cowl back off and finished welding them on. This way I could get to the back side and hammer weld them.

[Tinbender]

Back on the car again, after some finish work.

[Tinbender]

Re-checked the fit. Lots of measuring, more X braceing, then welded her in. I welded the drivers side, and left the passengers side loose for now.

[Tinbender]

Some finish work to the welds, then on to the passenger side. I made the plug welds with MIG, and welded the sheet metal with O/A.

[Tinbender]

The passenger side had some fit issues, but nothing too bad. A little coaxing, and I got her welded up.

[Tinbender]

Welded

[Tinbender]

A closer shot of the firewall. I went around the lower mount, to keep things simple. This is oxy/act welded & hammered. It keeps the area reasonabley straight, and it's still malleable enough for additional metal work. When finished it shouldnt need much filler.

[Tinbender]

Once the cowl was welded I added some braceing to the rear section of the car, in preparation to put it on the rotisserie. Up until this point, all the work was done on an original frame to help with alignment. The next surgury will be replacement of the rockers and floor. The frame would be in the way, and the car is going on a new chassis anyway.

[Tinbender]

With this rotisserie the car can be turned almost on it's side. It makes it much easier to do the floor and rockers.

[Tinbender]

Last one for now. The next step is to build the rockers. These are from Bitchin products, and come in two pieces. I'm joining the two pieces, using the running boards for alignment. I'll just tack them together untill I install them. I'll be making a sleeve, and plug weld the sleeves, along with stitch welding the seam into the sleeve / backer.
When finished these backers will make up a box section inside the rocker. Thats it for now, I gotta get to work!
TB.

[wayfarer]

Looking good Eric.

[Detonator]

Nice work! Saving a woodie is a very noble cause. See you at Woodies on the Wharf next June? I'll buy the beer! http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Boones]

thanks for sharing your progress. As a member of the NWC, its always nice to see another brought back to life.

[Skate Fink]

.........great shots. Thanks for sharing them.

[The37Kid]

Thanks for posting the progress photos, nice to see someone else can gas weld. I may have missed it but what year is it? Hope someone has floor pans in stock. Please post more updates when you can. http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Zeke]

Floor??? I thought that was swiss cheese.

Looks great Tin!

[MIKE-3137]

Wow, you've got a project for sure, but definitely a worthy candidate. keep the pics coming...

[Tinbender]

This project is turning out to be one of my favorites. It’s not the biggest challenge of my career, but it’s near the top of the list! You guys are right; there is something very satisfying about resurrecting a car like this one. Don’t wanna get all mushy, but I feel honored to be able to take part in this project. Thank you for the encouragement!