1/6/2008: Metalwork 10: A new year, and still more rust repair..
This entry will focus on the repair of the rust spot at the bottom. I
actually did this work gradually, during the period from August to
early January, but decided to save it for one post.
Looks minor, but once I started looking, I found that there was a
larger area where rust was developing, and a large dent. I
kept cutting until the metal was nice and solid.
There is an inner and an outer layer to this area of the car. This
inner layer patch was made in two pieces, and as you can see, both
have to have complex twists. It was very challenging to make, and
took me about 3 attempts to get right.
Once I got it to fit, it was tacked and butt-welded into place:
This panel was shaped on my english wheel, using a the “go cart slick”
technique to form the curve from top to bottom. This works by using a
rubber wheel to press the metal down against the curved lower anvil,
imparting that curve to the panel. This is different from the normal
usage of an english wheel, where your goal is to sandwich the panel
between two hard metal wheels and squeeze it to thin and stretch the
metal, which adds shape.
Using the soft upper wheel causes the panel to bend (in arrangement),
rather than being squeezed and changing the surface area (shape) of
the panel.
The result is somewhat like a slip roll, but you can put a
side-to-side bend into a panel of any length, as long as you can move
the panel back and forth in parallel straight lines.
The curved lip for the edge was formed using the
tipping wheel i’ve described before, and then fine adjusted the
curviture by tweaking that lip with my shrinker-stretcher.
The lip at the bottom was bent on a small benchtop sheet metal brake.
It took many hours to fine tune the patch and the opening in the car,
to get a perfect fit and butt-weld it into place:
The inner and outer layers don’t contact each other completely, so a
small patch was needed to fill the gap:
Just a little more grinding to do, and a small hole that needs to be
filled, and then I can finally call this patch “done”.
word of appreciation
11/2/2011 12:08:58
i just wanted to say thank you very much for the care and attention that you have put into documenting your repairs as well as into the construction of your website in general. it truly is a gift to all of us (and i am sure there are many) who are more amateur, or less brave, than you! that's one lucky little cab you have there!
best regards,
john
cab class of '64
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