Drivers side a-post (mostly!) done!

So, last night I got a visit from a good friend, who helped me to straighten the first welded a-post - a slice and dice job (if dice means weld):

Jim do not own "all dem fansy masjines!" they have at the Pitrate Customs shop, so a lot of the job last night got done by hammer and chissel! For instance, the lover rear corner of the patch panel, which aligns to the door:

I then got to show him a little, making the beads in the middle of the sheet metal. He then showed me, how to make the ends MUCH prettier, using the chissel.

He also straightened a few small dents - nothing you notice, when it is done, but you would, if it wasn't!

 Next time I have to roll the patch again, as all this tinkling with it bended it out of shape, and then I might get to weld it on!

Drivers side a-post beginning to get finished!

So, I know, it's been a while, since I've posted last. And it's not, because I haven't done anything on the project, my access to stable internet connections has just been limited.

The bottom of the drivers side a-post turned out to be a genuine nightmare! First, the plan was to change the outer skin, then the second layer as well, but when trying to relieve it from the inner structure, it tore it of like it was made of paper! So, in order to have an a-post with sufficient strength, all of the a-post was replaced.

Making a new inner post was a bit difficult, as the shapes of it was very complex, so it became a puzzle of sheet metal and weldings to make it into a part, similar to the existing. It was the welded to the saved parts, and the second layer was made to fit. Here the bead roller was of high importance, as we, with it and with the shrinker, was able to get the shape of a stamped out sheet metal part.

Wednesday before last I helped unpack from the last weekends show, and didn't get to do much but a little adjusting, before it was 22:45, and the piece needed only to be welded, and I then stopped - I'm very firm about stopping, while I'm ahead, before ruining anything, because "Ijust need to finish this, before going home!" and thereby ruining it.

Last wednesday I then got to weld the second layer on, but it didn't align. So tomorrow's project will be to slice it up, align it and weld back together again.