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.

Front brackets

Tonight I made a set of brackets to go from the cowl to the subframe:








Not much on a night, but some people were in the shop, so had to talk, eat cake and discuss music!

Keep 'em kruzin!
Dannerr

Long time...

After a long, turbulent time, I was finally abe to work on the car yesterday night!
I started fabrikating the brackets between the cowl and subframe, but didn't get to take pictures - so this was a short post, just to let you know, I'm still working on it!

A lot of talk and a little grinding

Yesterday night I didn't get much done, as there was visitors in the shop, who kept talking to me - even when I turned on the angle grinder!
Got the inner parts of the A post brushed down with a steel brush cup, and gave them some zink base coat, and then it was almost ten o'clock and time to go home.





Next week I might start making parts for replacement of the rusted through parts.

Keep 'em kruzin!
Dannerr

Other side

Yesterday night I cut out the other side of the lower cowl piece.
In order to get around the hinge, I made a cut in the otherwise very fine piece, Victor made for me.

 We made the piece to fit the bead, where the bonnet meets the cowl, and are cutting it there.

 The cut was done with a air driven hacksaw, in order to get the cut as thin as possible. And then I made the mistake of cutting to close to the edge of the replacement piece, so the saw bended the cut off and I had to align it to the edge - instead I should have made the cut about 1/2 inch from the edge, cutting through both plates. I'll do that next time!

 The doorpost is just as bad on the drivers side, so we're talking about spending a day fixing the bottom of those as well, now that I have gained acces.

So next week I'll either be doing the bottom of the doorposts or building more of the subframe.
At least, that's the plan - but as we all know, plans are made to be changed!

Keep 'em kruzin!
Dannerr

First piece cut out

So, yesterday it happened: I cut out the first piece of sheet metal to be replaced with new.
Still needs more rectangular pipe and steel for brackets, so I started with tacking the sub frame legs to the subframe, in order to release the welding clamps. Then the rest of the evening was spend with aligning and clamping the new bottom of the cowl to the existing, cutting through both of them at once with an airdriven saw and cut the old piece off (forgot to take pictures underway, this is taken afterwards).

Unfortunately the inner profile was very rusted, so I'll have to grind it down and give it some zink spray, before the new piece could be welded on.

So, now I know, how to do it on the drivers side as well - and if there is still no rectangular pipe and bracket steel next week, I'll grind down and spray, and start on the drivers side.