Custom bead rolling....lotsa pic's

A worthy thread that deserves more publicity ........

 

Wonderful thread...this site never ceases to amaze me.

 

Another trouble spot for wagons, the upper gate. It has a similar stance as the lower gate when closed, and as such, water lays along the inner window frame at the bottom.





Ice pick test....



The lower bend is fairly flat, going to a tipped flange in the form of an arc, the inside has some compound curves going to the window opening flange...









Next to get this bottom cut out and attempt to form it in one piece, flange to flange, for a easier job of replacing..

 

Took the upper gate off...



My tool of choice for removing spot welds is a 3" x 1/16 cutoff wheel. I also use the premium wheels made for stainless steel. It's worth the extra money when you don't have a brown cloud in the shop, like the el cheapo wheels leave, nothing but resin wearing away.
The upper layer of metal will start to turn blue when it gets thin and hot, letting you know you're getting close to the next layer. When you have a blue circle with shiny metal in the center, you are now in the second layer, grind around the blue a bit more and pry the layers apart..



With all the spot welds removed, here's what we find inside...







Note the deep pits. The big problem with just welding a hole closed is you don't know where the next pit is lurking, ready to break through your new paint.



Funny, with all the rust and scale inside, then you find this area of bare steel nice and shiny..



The inside will get media blasted to insure there is no more lurking issues and then epoxy primed before re-assembly.

Here's a better look at the shape we'll need...

 

To start the layout on the new metal, I wanted to find the center of the radius along the window opening. By holding a sanding disc on the flats and scuffing, it showed the edges of the radius...







Then laid out a pattern to be able to measure from the bottom crease...



....and transposed it to the new sheet...







The top edge was trimmed to size and the tipping wheel used to fold over the welding flange...





Comparison....



The bottom was marked with the tipping wheel and folded in the apron brake. Then trimmed to size, again using the tipping wheel to fold over the welding flange...



It's real close right now, just needs a bit of tweaking.













This was made using 18 ga, I think if I had the factory 19 ga metal it would have formed much easier..

 

Any way you cut it ... well done!

 

What wagon is that you're working on?

 

55 Chevy 210 wagon

 

That is crazy MP&C. I can't believe you could do all that with a bead roller. Nice job.

 

What do you use for a bottom wheel when you use the spherical wheel on top?

 

Nicely done; what would be your total time with that piece?

 

Very nice work...I second the question as to what you use under that Spherical Wheel on top???

Tim the Toolman

 

Look on top of the yellow box in this picture, the bottom die is the 75A durometer red skateboard wheel...




I would guess there is about 2-1/2 hours in the layout and fabrication of that piece. Could have been a bit quicker, but part of the time is from dragging your feet, wondering if it is actually going to work..

 

made a stand for my anvil today and dressed it up a little with some help from my Baileigh bead roller

 

Made some dies out of Derlin so I can roll the Econoline body shape into some aluminum and make some light weight doors.

 

This is a amazing thread . Thanks to everyone for sharing their projects and skills.

 

You guys rock! thanks for sharing.

 

Wow freaking awesome stuff !


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Not sure I even want to post a pic here as you guys are amazing, but I must say thanks as I would have never even known you could do this stuff on a roller.

After seeing this stuff and emailing Ric at BigWig Race Cars, I decided being hellbent on trying this stuff myself, I bought a 36"MB unit and gave it a shot. Rolled a few panels for the car I am building and this last week decided to give it a go at doing some art.

First shot at doing anything like this at all, learning as I go and if I count right, I think this is only the 9the piece of metal I have put through the roller including the 6 panels on my car and 2 tester pieces.

I think I am rolling with a bit to much pressure? But again just starting to learn this stuff. Thanks for posting up your work guys it is truly inspirational

 

Not as good as some of the quality work on here but I'm just messin round, made this one for my race car

 

Here is a copper Rat Fink...


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Few things I have done.


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Very talented Jamey. I bought a lot of the Jamey Jordan series stuff, but my bead rolling does not look like yours. Ha Ha.

 

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I have to come back to this thread every month or so to check out the new postings and I'm always re-impressed. Its just unbelievable the skills and vision you have Jamey. Extraordinary talent indeed.

BOutlaw

 

Amazing. I never knew a bead roller could be so use full

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