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Projects '57 Cadillac Build - "Emily Jo"

Discussion in 'Traditional Customs' started by JohnnyDeuce, Dec 19, 2014.

  1. Rocket Man 57
    Joined: May 21, 2016
    Posts: 33

    Rocket Man 57

    Love the work you're doing. Both encouraging and inspiring. I'm doing similar things to a 57 Olds. My rear bumper ends are pretty rusted and searching for them has proven as fruitless as your search. As rusted as mine are, they're still in better shape than the ones you repaired. Thanks for showing how it's done. If you had planned on chroming them, would you have done them any different?
     
  2. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Thanks for the kind words, Rocket Man!

    To answer your question - The bumper ends are not done to what I personally believe is an acceptable standard - They just look "OK" for now, because I needed to get her all buttoned up and put together before the end of class, so I could drive her to storage. I intend to finish them to an acceptable standard while attending the next class.

    As far as the details required for chroming - I'm not sure about prep requirements, with the exception of ensuring they are flawlessly metal finished - Because chrome MAGNIFYS flaws, as opposed to hiding them.

    Hope that helps somewhat - Keep wrenching!
     
  3. treb11
    Joined: Jan 21, 2006
    Posts: 3,681

    treb11
    ALLIANCE MEMBER

    anybody ever tell you that you look like Robert Earl Keen?
     
  4. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    OK - Back in school at the Hot Rod Institute in Rapid City, SD and I just drove the Caddy IMG_20160701_143244_630.jpg back into the shop today ~

    Can't wait to get started on all her bodywork!!!
     
  5. Rocket Man 57
    Joined: May 21, 2016
    Posts: 33

    Rocket Man 57

    Been waiting for an update, now get to work.
     
  6. Dimadee
    Joined: Feb 19, 2013
    Posts: 105

    Dimadee
    Member

    Yeah....like he says. Make ya Mother proud! ;-)

    Good to see you back in the workshop.
     
  7. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Thanks for the encouragement, Fellas!

    Here's a couple posts of her new back seat:

    IMG_20160701_143942_095.jpg IMG_20160701_143949_111.jpg
     
  8. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    And here's some shots of the bodywork I have ahead of me:


    IMG_20160701_151740_515.jpg IMG_20160701_151756_074.jpg IMG_20160701_151803_281.jpg IMG_20160701_151827_715.jpg
     
  9. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Also gonna nose the hood and punch some louvers in it - Can you believe the plastic emblem that fits in the bezel on the hood costs $299.99 for a reproduction? Crazy... IMG_20160701_151917_366.jpg
     
  10. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Notes from the first week of class:

    Hot Rod Body Fabrication

    20160627

    TOOLS OF THE TRADE

    Sheet Metal Cutting Tools -
    Aviator Snips – Used for small intricate cuts
    Straight Snips (yellow handle)
    Right Snips (green handle) – For curved cuts to the right
    Left Snips (red handle) – For curved cuts to the left
    Beverly Shears – Ideal for cutting outside curves
    Foot Shear -
    Ideal for cutting large sheets of metal
    Provides perfectly straight cut edge
    Electric Shear -
    Ideal for cutting shapes out of large sheets of metal
    3” cut off disc
    Not recommended for thick metal or very long cuts
    Ideal for removing a section of metal from the center of a panel
    Hack Saw
    Hole Saw –
    Ideal for cutting large holes in the center of sheet metal
    Blair Tools is a good supplier
    Chassis Punches (Knock out punches) -
    Similar to Dimple Dies
    Hand Punches -
    Allows punching of precise, clean and accurac wsmaller hoods
    Drill -
    High pressure – Low speed
    Bead Roller
    Reciprocating Sawzall -
    Air Hammer
    Air Punch/Flanger
    Plasma Cutter

    Hammering and Dollying Tools

    Hammers – Martin and Snap-on
    High Crown = high contact patch = “Inside Hammer”
    Low Crown = large contact patch = “Outside Hammer”
    Dinging Hammer = Flat face used to flatten metal
    Pick Hammer = Pointed – Used to bring up low spots
    Domed Hammer = High crowned face, used to form curved surfaces
    Shrinking Hammer
    Slapping Hammer
    Mallets
    Plastic, for forming metal
    Leather Wrapped, to limit marring the metal
    Wooden, for compound curves – Make your own from baseball bats
    Ball Peen = Not designed for sheet metal shaping
    5 pound Sledge = Not designed for sheet metal shaping

    Dollies - Deep forged, hardened and tempered alloy with highly polished working faces
    Toe Dolly = Long and thin for accessibility to narrow areas
    Heel Dolly = Designed to reach into sharp corners
    General Purpose Dolly = “Railroad Tie”
    Unlimited application
    Wedge Dolly = High Crown Dolly
    Comma Dolly = Large radius face ideal for high crown panels
    Leaf Dolly = Many uses on low crown panels
    Stake Dolly = Designed to be clamped in a vise
    Post Dolly = Used for planashing metal
    Bulls-Eye Pick = Ideal for raising low spots

    Nail Gun – Pulls out dents without needing to drill holes

    Spoons - “Dolly on a stick”

    Sheet Metal Shaping Tools

    Planishing Hammer – Pneumatic hammer designed for smoothing lumpy sheet metal and creating crowns in panels – Planish means “Smooth Out” - MUST USE HEARING PROTECTION

    Shrinker/Stretcher – Pneumatic, Hand and Kick
    Ideal for fabricating curved flanges and channels, braces, wheel well openings, etc.
    Capable of stretching or shrinking up to 18 gauge steel
    Much easier to stretch than shrink

    Sawhorse – Home made excellence

    Sheet Metal Brake – 6' is the best size

    Slip Roller – 2 rollers on the bottom and one on top – Puts a curve in it w

    English Wheel – Takes the shape of the lower wheel

    Power Hammer – More powerful than a planishing hammer

    Louver Press – Punches individually in up to 16 Gauge – 3” is the normal Hot Rod type

    SANDING TOOLS

    Disc Sanders

    High speed, rotary 3”, 5” and 9” sanders, 24 and 36 grit
    Vixen File – Used to ID highs and lows – Mark the metal – Use a 30 degree slide
    Bastard File – Diff shapes and sizes
    Die Grinders – Used for polishing, grinding and de-burring

    SHEET METAL RESTORATION

    Learn to “read” the metal
    Don't always need to strip to bare metal
    Reasons to strip the paint
    Cracked, crazed, peeling, stone chips, wrinkling, excessive fading, excessive film thickness

    Damage Analysis
    Contours and contoured panels
    Provide strength and rigidity
    Must be restored to regain panel strength
    Fenders typically have high crowns and very rigidity
    Roofs/hoods have lower crowns and tend to have an “oil can” effect due to less strength

    Elasticity
    A panel's flexibility
    Elasticity allows a panel to return to its natural shape and contour without signs of stress of distortion
    “Reverse the Damage” to return panel elasticity

    Direct Damage: Point of impact
    Indirect Damage: Buckles created by the damage
    **Dolly on Direct Damage, Hammer on Indirect Damage**

    Sanding
    Start with 40 grit, go to 80 grit until bare metal, then 180 grit

    FOUR STAGES OF RESTORATION

    STAGE 1: Analyze the Damage
    Accurate analysis will simplify and shorten the remaining stages
    Ask yourself:
    How did damage occur?
    What is preventing it from returning to original shape?
    What type of damage exists?
    In what order did the damage occur?
    What was the point of impact?
    What was the extent of the indirect damage?

    STAGE 2: Rough Out

    STAGE 3: Smooth Up
    Most of the time is spent in this Stage

    Hammer and Nail Gun
    Advantages
    No holes to fill
    access to back of panel not required
    Pull dents with large slide hammer or t-handle
    Can shrink with it – Use gun without nail to zap it
    Can also install molding clips
    Disadvantages
    Nail Gun cost – Approx $600ish
    Nail cost

    Good brand: spitznagel dent fix

    Hammer Off Dolly in this stage

    Stretched/Displaced Metal
    “Oil Can” effect
    Metal pops in and out

    Stretching Shrunk Metal
    Hammer ON dolly
    Metal is between hammer and dolly
    Used for smoothing metal and removing sharp wrinkles
    Creates a “ringing” sound

    **EASY TO STRETCH – HARD TO SHRINK**

    STAGE 4: FINISHING

    Returns panel to original shape
    Condition is – Ready for paint
    Finishing is achieved in one of 2 ways:
    Metal Finishing – No use of filler, goes straight to a filling primer
    Finishing with Filler – Restoring panel to within 1/8” of original contour and using lead or polyester filler to achieve the final contour and smoothness

    Polyester Body Filler – Used only AFTER the smooth-up stage of panel restoration

    **Use a metal applicator**
    Apply over welded or leaded seams, to fill pinholes
    Cannot be used to create a body line

    Golf Ball of Filler to 1 inch of hardener
    Don't mix and walk – mix when next to the work

    OXY-ACETYLENE WELDING

    Settings

    Welding – Acetylene = 4-5 psi
    Oxygen = 5-7 psi

    Shrinking – Acetylene = 4-5 psi
    Oxygen = 5-7 psi

    Cutting – Acetylene = 4-5 psi
    Oxygen = 20-25 psi (Oxidyzing flame w/extra pressure to blow the molten metal away)

    FLAMES

    Pure Acetylene
    Bright orange-yellow
    Wavy, smoky, producing carbon soot
    Not hot enough for welding

    Neutral
    Equal amounts of oxygen and acetylene
    Approx 5900 f
    White, blunt inner cone is present
    No visible acetylene feather around inner cone
    Nearly colorless, envelope with bluish to orange edges
    Used commonly for welding. The flame consumes all the oxygen in the atmosphere around the weld to provide an un-contaminated shield for the weld

    Carburizing
    More acetylene than Oxygen
    Approx 5700 f
    Long, intensely bright inner cone
    Whitish acetylene feather around inner cone
    White envelope with light orange edges
    Used for heating and leading

    **TURN THE OXYGEN OFF FIRST**
     
  11. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    She's got a new brake system now - Caddy Daddy's power brake kit for drum brakes

    Gotta test drive her, and fill the new hole in the floor - But those are good problems to have! IMG_20160710_105422_228.jpg IMG_20160710_105430_969.jpg
     

    Attached Files:

  12. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Been steadily working on learning how to TIG weld - Finally getting it, after a month of training and practice!!!

    IMG_20160706_084147_421.jpg IMG_20160706_102254_383.jpg IMG_20160706_141631_951.jpg IMG_20160713_091259_417.jpg IMG_20160713_091305_891.jpg
     
  13. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    IMG_20160713_140721_212.jpg IMG_20160713_160525_075.jpg IMG_20160713_160806_634.jpg IMG_20160713_161617_448.jpg IMG_20160713_161628_960.jpg IMG_20160713_161656_770.jpg IMG_20160713_161712_874.jpg IMG_20160713_161735_716.jpg IMG_20160714_102851_506.jpg Metal shaping and TIG work with this gas tank competency test - Pretty good way to check your skills!
     
  14. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    IMG_20160714_145217_267.jpg IMG_20160714_145237_635.jpg IMG_20160714_145240_894.jpg IMG_20160714_145243_714.jpg IMG_20160714_145254_635.jpg IMG_20160714_145257_590.jpg IMG_20160714_145313_732.jpg IMG_20160714_145324_787.jpg IMG_20160714_145343_645.jpg IMG_20160714_145355_920.jpg More shots of the gas tank
     
  15. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

  16. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

  17. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    IMG_20160725_164458_002.jpg IMG_20160725_164514_777.jpg IMG_20160725_164523_427.jpg IMG_20160726_100259_552.jpg IMG_20160802_164344_287.jpg IMG_20160802_164348_607.jpg IMG_20160802_164408_030.jpg IMG_20160802_164420_530.jpg IMG_20160802_164425_502.jpg Still more gas tank shots
     
  18. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    IMG_20160804_111823_131.jpg IMG_20160804_111836_531.jpg IMG_20160804_111850_724.jpg IMG_20160804_111915_700.jpg IMG_20160805_083542_823.jpg IMG_20160805_083612_106.jpg IMG_20160805_083618_506.jpg IMG_20160805_093745_915.jpg IMG_20160805_163129_304.jpg IMG_20160805_163136_391.jpg Finished up with the tank - Now on to the Caddy!!!
     
  19. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Some nice pics of Emily Jo ~

    IMG_20160714_171516_182.jpg IMG_20160714_171531_293.jpg IMG_20160714_171556_122.jpg IMG_20160714_171611_797.jpg IMG_20160714_171635_362.jpg IMG_20160714_182757_586.jpg IMG_20160718_110438_939.jpg IMG_20160718_110447_644.jpg IMG_20160718_110457_977.jpg IMG_20160718_110513_635.jpg
     
  20. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    IMG_20160725_145943_921.jpg IMG_20160725_150043_645.jpg IMG_20160725_150126_873.jpg IMG_20160725_150555_909.jpg IMG_20160725_150840_979.jpg IMG_20160725_150848_227.jpg IMG_20160725_150912_341.jpg IMG_20160725_151155_734.jpg IMG_20160725_151259_210.jpg Three of us here at the school have 1957 4 door cars, so we took a group pic!
     
  21. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Tearing out these original parts for an upgrade - They're all for sale, if anyone wants them!
    IMG_20160803_101206_959.jpg IMG_20160721_144034_429.jpg IMG_20160721_144127_624.jpg IMG_20160721_144216_281.jpg IMG_20160721_144241_333.jpg IMG_20160721_144255_850.jpg IMG_20160721_144743_958.jpg IMG_20160721_144749_775.jpg
     
  22. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Generator is gone, because it wasn't charging. In its place is a 140 Amp, 1-wire alternator - Works great, too! IMG_20160803_101216_845.jpg IMG_20160803_102832_233.jpg IMG_20160803_102846_364.jpg IMG_20160803_110427_661.jpg IMG_20160803_141727_607.jpg IMG_20160803_141732_994.jpg IMG_20160803_141738_559.jpg
     
  23. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    New Carburetor - 600cfm Edelbrock - Performance tuned

    Had to fabricate a bracket by flipping the "ear" on it - Not beautiful, but it works! IMG_20160803_212525_813.jpg IMG_20160804_090109_307.jpg IMG_20160804_090122_001.jpg IMG_20160805_145418_048.jpg IMG_20160805_163907_301.jpg IMG_20160805_191840_150.jpg
     
  24. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Here's some more recent YouTube videos of her:





     
  25. Rocket Man 57
    Joined: May 21, 2016
    Posts: 33

    Rocket Man 57

    Good to see this progressing.
     
  26. Caddystew
    Joined: Dec 30, 2009
    Posts: 94

    Caddystew
    Member
    from East Texas

    Hi Johnny,
    Just found your thread and could you help me with how you handled the transmission rod connection to the Edelbrock?
    I want to convert my carb as well and cannot get the bracket correct?
    Did you notice a difference when you went to the Edelbrock?
    Thanks
    mark
     
  27. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Hey, Mark ~

    Actually, I'm still trying to get the new carb and linkage dialed in properly.

    I had to modify the bracket one more time to lengthen it, and it's still not 100%

    The problem is compounded by the "Push-Pull" difference between the old carb and the new one.

    Best advice I can give is - Look at how the stock brackets are set up and use them as a template. 1007141335b.jpg Check out the attached pic of the original linkage hooked up - Be sure you figure out a way to get the new linkage on the Edelbrock to PUSH BACK - Like the original did.

    Good luck!
     
    Last edited: Aug 16, 2016
  28. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    OK - Diving in to the body work now, and Emily Jo appears to have a bit of a bondo problem - Unfortunately!!!

    But - That's why I'm in this class, I guess. Gotta knock these dents out!!! 20160815-Grinding-01.jpg 20160815-Grinding-02.jpg 20160815-Grinding-03.jpg 20160815-Grinding-04.jpg 20160815-Grinding-05.jpg 20160815-Grinding-06.jpg 20160815-Grinding-07.jpg 20160815-Grinding-08.jpg 20160815-Grinding-09.jpg 20160815-Grinding-10.jpg 20160815-Grinding-11.jpg 20160815-Grinding-12.jpg 20160815-Grinding-13.jpg 20160815-Grinding-14.jpg 20160815-Grinding-15.jpg
     
  29. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    Here's how she ended the day yesterday ~ IMG_20160815_163722_149.jpg IMG_20160815_163733_553.jpg IMG_20160815_163756_217.jpg
     
  30. JohnnyDeuce
    Joined: Jul 14, 2009
    Posts: 158

    JohnnyDeuce
    Member
    from USA

    IMG_20160816_112438_213.jpg IMG_20160816_112448_510.jpg IMG_20160816_112523_113.jpg IMG_20160816_131217_019.jpg IMG_20160816_131221_936.jpg IMG_20160816_131230_329.jpg IMG_20160816_150236_900.jpg IMG_20160816_150252_537.jpg IMG_20160816_150306_066.jpg IMG_20160816_150328_064.jpg IMG_20160816_150343_197.jpg Uncovering more and more problems...
     
    Last edited: Aug 16, 2016

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