Let's see some sheet metal shaping

Well tonight's task was to remove the bottom detail of the lift gate and sandblast the remaining structure in prep for epoxy primer. The lower edge did have a flange folded up, so a slit was cut along the edge and the door skin vise grips were put to use...







Next, the spot welds inside were ground out.....







Media blasting..... nice to finally see through the glass!



The media blasting revealed a few more holes, and numerous pits, many of them close to breaking through.







With all the other new metal going in the bottom, there's only one thing to do. Using the tipping wheel..........









Comparing to the pitted version.....













Next we'll need to do some corking to add the trim hole pad details.

 

Now to address the mounting pads for the window molding....

Here's the new "anvil", made from some phenolic sheet.....





Put an alignment mark on the anvil, fitted it to the originals, and added the mark there as well. Then transposed those marks to the new piece...





Anvil was located, and clamped in the vise to hold it's location





Started with the barrel end hammer.....









For the ends, I used a rounded tip chisel....





....and then another "anvil" to clean up the hammer marks a bit...







Here's all the tools used....



Touched up a bit with a sanding disc, looks close enough.... One down, 4 to go...

 

Very nice as usual! Which Phenolic sheet do you use?

http://www.usplastic.com/catalog/default.aspx?catid=679&parentcatid=795

Thanks!

 

Not sure which grade it is, I picked up this partial sheet about 25 years ago, was being thrown away. Looking at the prices on the link you posted, I'm glad I didn't leave it!

 

Great pics and info, thanks for sharing..

 

Here's an air dam we made for a 67 Camaro. It'll be used only on the track, as it's removable with 1/4 turn fasteners

 

http://www.youtube.com/watch?v=OTu0_NX-xzY&feature=youtu.be

some tiny shaping

 

That's a handy little bastard!

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Last night I worked to finish up the pad details on the inner structure of the lift gate.... The center one was wider, so I used the same phenolic and just added a wider detail to the opposite side. I missed showing this earlier, but a handy-dandy battery saw works well to remove the bulk of the material, sawing parallel cuts and then just working the saw side to side to clear out the remaining....





Once cut out, the sanding disc is used to cut down the angled sides and touch up the bottom..



This compares the two, showing the difference in width...





Alignment marks transposed from the original, and guide marks indicate the area in need of hammering...





I had a request to show the hammering procedure, so here's another video attempt. The first one is using the phenolic anvil clamped against the work piece in the vise, the second uses 1" square stock as an anvil to clean up the hammer marks a bit...

http://s5.photobucket.com/user/rmcc...y Wagon Restoration Album 3/Video232.mp4.html

http://s5.photobucket.com/user/rmcc...y Wagon Restoration Album 3/Video233.mp4.html

...also sounds like I have a loose hammer handle, something for another day....

Then the sanding disc was used for final cleanup. Here's the finished piece, just needs a couple holes drilled....

 

Neat!
How long does it take to turn a thumb nail purple? LOL

 

Some re-assembly....

 

Wow; nicely done!

 

What are you using for media? I've been seriously looking at those sales on soda blasters from Eastwood. They seem to come up on a regular basis, and I've got an old metal hopper that might become my blasting cabinet some day. I'm beginning to think you're wasting time recreating other car parts... it might be faster to just make your own car from scratch! You've got some great talent there. I've tried enough to know it's nowhere as easy as you make it look.

 

I'm using this stuff:




Here's what it looks like, along with a few strays of Black Beauty.

 

Looks almost edible. I had assumed most media blasting was done with shredded plastic, but this stuff is alluvial garnet.
http://www.barton.com/waterjet-abrasives/hpa-high-performance-garnet-abrasives/

 

RHD '64 Impala's apparently used a Pontiac dashboard - we were asked to scratchbuild a RHD version of an SS dashboard (with some mods)......kicked my ass for a while but got it done eventually. Budget constraints meant I didn't take this to a full metal finished state....

 

Very nice work BarryA!!

 

Thats impressive, Barry A

 

Putting some 39 ford tails in a 60's Chevy stepside. I had to extend the fenders a couple inches at the bodyline to make it look right. The first fender I had to do in 4 pieces. The second one I got in 2. Those double reverse curves are a mother to do by hand.

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Cheers Hasty, Laidout.

Niceguy that's some nice work!

 

That Looks great. nice work

 

Wow, very cool Barry..

 

you guys are doing some great work!! thought I'd chip in again with a few pics of some work I did on a 64 Falcon coupe. The poor thing had been in the wars ...best thing to do was cut the old sections out and start again with fresh metal..20 guage zintec

old..







new...











it was quite tricky with the upper line having a gentle curve in it from front to rear...



but it actually came out pretty good and required only around a cup full of filler to finish off before paint.

 

Here's a bus I just finished hand made guards,and all the shaped panels.





Cheers Steve

 

Who's been a busy boy then

 

Very cool! what gauge did you use?

Awesome!

In awe!

Those inner shrink marks, how did you do that?
Cool rig!

 

I would have said, with Thumb Nail dies
(I love mine )

 

Wow. Some serious talent on here using some serious machines!

Might as well throw my hat in the ring so here goes. Here's a hand made 64 Comet lower quarter I did a year or so ago - before and after. No pro but pleased with the results.

Dan

 

Cool Dan
It's all about having a go
(some of us only "pretend" to be pro's )

 

I ran them in raw steel for about a year until I finally found the time to throw a bit of paint on them.
My old girl has been a daily driver for around 10 years, so it's always a "work in progess" lucky the local coppas know me, at one stage I only had one fender on, then 2 then 3 & finally the 4th after about 6 months