View Full Version : Roof rust repairs
If you've seen a hole in the roof that is noticeably up from the drip rail, chances are it has rusted from the inside-out, as you'll soon see. Any attempts to repair without opening up the roof for some exploratory surgery will be short lived. So simply tapping the holes inward and filling with bondo is a good waste of a paint job, and will come back to haunt you in a year or two.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM4765.jpg
While waiting to do some painting, might as well cut up something. But not until after a quick check on the inside as well to see the extent of the problem.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5180.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5181.jpg
Looks pretty ugly, and will require taking out more than I originally thought. Time to mark out the cut line.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5183.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5184.jpg
If you've never seen what holds the roof on, there are about a gazillion spot welds that hold it down to the gutter. Maybe not that many, but when you are drilling them out, well it seems so.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5187.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5188.jpg
Once all the spot welds are drilled out, it is easily removed. This is going from bad to worse. The rain gutter doesn't look too healthy inside.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5190.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5193.jpg
In true domino fashion, time to lose the gutter, and the profile shot will show how they are assembled together.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5196.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5199.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5200.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5202.jpg
Maybe this would make the start of a good Vista Cruiser? After some much needed sheet metal replacement takes place on the inside, we'll try our hand at making a rain gutter.
Let's pause here and clarify the major components we're working with:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%202/RoofStructure.jpg
The rusty pieces came out as good as could be expected, and were limited help in forming new pieces. Some of the measurements had to be transposed from the opposite side of the roof, which was virtually flawless. After further inspection of the affected area, I'm thinking it was a condensation problem, and the moisture followed down the roof crossmember just like a gutter. The car must have been parked with a downhill slope to that side.
Gaining access:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture067-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture068-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture070-1.jpg
Here's a good indicator for using the 3" cut off wheels as a grinder for removing spot welds. The top layer starts to turn blue when the metal gets thin and hot. Once you are through to the second layer, you will see the bright metal surrounded by the blue ring. Time to stop and pry them apart.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture069-1.jpg
This video will show the spot weld removal process in a little better detail..
https://www.youtube.com/watch?v=nb49MgRPzvY
Our removed parts, so far....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture077.jpg
A trial run at rain gutters
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture063-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture064-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture079.jpg
Fabricating the new pieces
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture082.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture083.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture084-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture086-1.jpg
There was one more section that needed repair, specifically the section holding the headliner bows. Looking at the next pic, the left red circled area is what it should look like, and the right red circled area shows where some of the rust spread, weakening the headliner bow support. Time to cut this out, bend up a replacement, and weld together.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture088A.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture089-2.jpg
Dress the exposed welds a bit, and the rest will be cleaned up in the sand blast cabinet in preparation for epoxy primer. Then this stuff can start going back together.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture092-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture094-2.jpg
Well most of the roof patches are just about done, ready for paint, but we'll need the rain gutter as well, so let's get that done so it can be painted at the same time. The section needed was about 31" long, and you tend to get crisper bends on shorter sections (especially with worn out machinery), so I made two pieces 16" long. Here's the bend process:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture095-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture096-2.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture097-2.jpg
These were all done in the apron brake, with the last one accomplished using the clamping section of the brake to flatten out the bend. Next, a mark is made to cut the "tail" to size, and this cut will be done using a 3" x 1/32 cutoff wheel. To prevent from cutting through into the back side, slide a piece of scrap under the "tail".
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture098-2.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture099-2.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture100-1.jpg
Once the tail is cut this short, we'll need to resort to the press brake with some flattening dies to compress the fold flat, mimicking the factory original. This could also be done using a good flat body hammer.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture101-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture102-1.jpg
Then it's back to the apron brake, and with the newly made fold facing out, make a slight bend to form the curved surface you see on the outside of the gutter.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture103-1.jpg
Then the rest of the bends, and a trail fit.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture104-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture105-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture106-1.jpg
Although the gutter was fairly straight and needs to have a slight radius to match the roof, the heat from the plug welds should be sufficient to shrink the back edge and draw the gutter in tight to the car where it belongs. Now where's the smiley with the fingers crossed when you need it? ;)
Well the epoxy primer has dried so let's get started on the drip rail install. Some epoxy primer was also painted on the top edge of the quarter the other day, in an attempt to prolong the lifespan this second time around. Plug holes were drilled, and the first piece was welded in place.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic001.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic002.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic004.jpg
All the plug welds were ground flush as the drip rail will position on top of this for welding. The next piece was overlapped and welded in place.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic005.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic006.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic007.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic008.jpg
And now for the drip rail
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic010.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic013.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/pic015.jpg
Inside roof structure welded back in the wagon, and the welds dressed.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5692.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/HPIM5694.jpg
For the roof filler panel, I needed to make some dies for my Lennox, a reciprocating machine used to form sheet metal. But first let's take a profile template.. ( I should point out that this is by all means something that someone could do with a simple hand brake, it would just take a bit of determination and finesse.)
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture122.jpg
As the machine has 3/4" square tool holders, this 3/4" steel flat bar looks like it will work......
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture123.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture124.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture125.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture126.jpg
A sample piece of 19 ga is run through and test fit on the car.....
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture128.jpg
The wavy metal at the top indicates the dies are a bit tight in that area, and are planishing, or stretching the metal.
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture129.jpg
So we'll tweak the dies to see if we can get it a little closer....
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture142.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture143.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture145.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture147.jpg
The repair panel came out much better this time.....
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture148.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture149.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture150.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture151.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture152.jpg
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture153.jpg
This is a good rough start, and we'll fine tune it to better fit over the area with the hole.
Test fitting the repair panel over the area with the hole.............
http://i5.photobucket.com/albums/y167/rmccartney/Peter%20Romano%20Roof%20Repair/Picture129.jpg
Looking at the front, the panel needed just a bit more crown....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture441.jpg
And the rear needed just a bit less....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture446.jpg
So with the Go Kart slick mounted up and ready to go, a 6" then 3.75" radius lower anvil added the crown needed for the front and a 24" radius flattened out the rear for a much better fit. The sharp corners are also trimmed to a nice sweeping radius to prevent the shrinking effects from compounding, as they would in a sharp corner.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture443.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture444.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture447.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture448.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture450.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture451.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture452.jpg
These panels are about 4" high and put the weld up above the roof boxing structure, so planishing will be easily accessible to give us a better job.
The standard cone tips with my spot welder do not have the clearance needed to duplicate the factory spot welds inside the drip rail......
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture107-1.jpg
Looks like we'll have to make our own, so lets start out with some flat tips, and start on the bottom. This one has to be trimmed down pretty short to fit in there because of the outward crease just below the drip edge:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture110.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture111-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture113-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture115-1.jpg
Then to shape up the top one, it will need the extra length to reach past the drip edge:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture117-1.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture118-1.jpg
Then a test fit, this just may work!
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration/Picture120-1.jpg
Marking out the roof for the new replacement patch.....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture471.jpg
Then another line was dropped down about 1/4" to be used for the "rough cut". A cutoff wheel was used and then trimmed with the snips.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture472.jpg
For the outer sections, a section was marked off just wider than my sheet metal pliers. Then the spot welds, which were visible from the top, were drilled. A cutoff wheel was used to grind through the end(s) of the section being removed. Then the sheet metal pliers used to rock the panel back and forth to break the spot welds loose.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture473.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture475.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture477.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture478.jpg
Got some epoxy on the back side of the new roof patch...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture482.jpg
The lower corners of the opening were trimmed to size so that the roof patch could be clamped down into the drip rail. This will help to get more accurate markings on the roof skin for trimming the rest of the opening.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture489.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture488.jpg
C-Clamp vise grips added to secure the overlapped panels for marking, then a straightedge used to read the crown of the roof to insure there were no dips or puckers along the top of the joint....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture490.jpg
My favorite scribe, a local auction purchase...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture491.jpg
Scribing the roof panel
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture492.jpg
Not much to spare! Trimmed the opening with some offset snips...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture493.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture494.jpg
Corners touched up with a 1-1/2" drum sander
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture495.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture498.jpg
Clamped in place to hold the shape. Note the butt weld clamps will be removed at welding for a tight fit-up.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture496.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture497.jpg
In an attempt to limit the heat on the roof panel, I wanted to try some .023 welding wire. I had ordered .023 ER70S-7, but what actually showed up was EZ Grind. I guess I was destined to try this stuff out...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture613.jpg
After about 45 minutes of changing wire, rollers, and trying different settings on the machine, we found dialing it in for 3/16 thick steel and using 1/2 second weld "application" showed about the best results.. Seems odd as the metal was 19 ga, or about .038 thick..
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture614.jpg
front:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture615.jpg
rear:
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture616.jpg
Comparative size of the weld proud.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture617.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture618.jpg
Using the special made tongs, we did the spot welds first to insure the panel was pulled down into the drip rail tightly..
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture622.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture619.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture621.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture623.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture625.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture626.jpg
Then the panels were aligned and tacked, starting at the rear and working toward the front...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture627.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture628.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture629.jpg
Full penetration welds....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture630.jpg
The patch should be well high enough for planishing.....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture631.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture632.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture633.jpg
Well after a week in FL, time to get back in the shop.. I wasn't totally pleased with the .023 EZ grind, but in all fairness I think some of the issue is my welder. It never has been too keen on .023 wire, so looks like my BIL is going to get a new roll of the EZ grind wire for his Hobart.
Put the .035 ER70S-7 back in, dialed in the settings for 3/16 thick steel, and ran some test welds...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture648.jpg
Front side....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture645.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture646.jpg
Rear side....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture647.jpg
Comparing the EZ grind to the -7, shows less splatter with the -7...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture649.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture650.jpg
The roof cross member made part of the weld seam inaccessible, so it was removed on one end for planishing access...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture652.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture653.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture655.jpg
Welds ground down to just above panel surface...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture656.jpg
Our planishing implements this evening.... Low crown hammer and used the Pexto blocking hammer as a dolly...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture659.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture660.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture661.jpg
This shows the weld dots planished....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture657.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture658.jpg
Full penetration welds.....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture662.jpg
Weld, planish, grind, repeat.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture668.jpg
We're about halfway done, hope to finish it up tomorrow...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture669.jpg
Got the bulk of the welding done. planished, and started to dress the welds.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture671.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture672.jpg
This will still need some final metal bumping when finished, but this looks much better than those rust bugs staring at you!
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture673.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture674.jpg
Sorry I didn't have as many in-process pictures, got in a rush.... until next time..
Again Robert wonderful work. Thanks for sharing!
carls 56 (RIP 11/24/2021)
02-19-2014, 06:03 AM
thanks for sharing Robert.
Thanks for the comments guys. Some more cleanup work on the roof weld, didn't get much for in process pictures, but then this part gets pretty boring anyhow...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture675.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture676.jpg
Inside...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture677.jpg
I'm pretty pleased with how it turned out this time. Still has some metal bumping needed to address some highs and lows, which we'll work on next time in the shop, as well as welding in the last pieces of the lift gate..
chevynut
02-24-2014, 06:56 PM
Hey Robert, very nice work! Is this recent, or from long ago? I thought you did that years ago, but I may be wrong.
Anyhow, do you use .035" wire on all sheetmetal work? I've been using .024" but I've never tried anything else. I can't get quite the penetration as you get. My MIG is just a 110V unit and I usually have to set it pretty low to avoid burning through.
The initial was from previous, but I recently cut it back apart as I never have been pleased with how it turned out. Much better now that the seam was up high enough for planishing.
My welder has always been partial to .035 over the .023 spool I have here. For welder setup, I normally recommend setting up heat first to insure full penetration weld, adjust the wire feed just fast enough to prevent blow out, and weld size is controlled by the duration time.
As shown earlier in this thread, I set my welder up for about 3/16 steel. The weld amount is controlled by length of weld duration, which I used about 1/2 second.
567chevys
02-25-2014, 11:03 AM
Hi Robert , Great Stuff !!!! Thanks for posting it !
Thanks Sid
Maddog
02-25-2014, 04:04 PM
The real challenge is, can you make an outside patch for a Nomad with the bead running across?
I'd need the "sample" sitting here to make some dies for the bead detail..
Maddog
02-25-2014, 05:13 PM
I have never seen anyone make a curved panel with the beads cross ways. If you can you'll make a ton selling patch panels for the typical rusted Nomad roofs.
Maddog
02-25-2014, 05:14 PM
I'd need the "sample" sitting here to make some dies for the bead detail..
For a good test, just take that same wagon patch and run some Nomad beads across it....................
If it can be done I bet Robert could do it. He is very talented!
My nephew Chris stopped by to help this morning so we decided to work on the roof a bit. Added a guide coat and skimmed across it with the vixen file to show the high spots...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture724.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture726.jpg
To help keep inside and outside guys on the same page, some reference marks were added from the door opening back, on inside and outside of the roof.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture730.jpg
Worked the highs and lows, and thought we'd compare it to the other side. Making a profile template to match the good side...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture728.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture727.jpg
Shown at about 6, 12, and 18". We're getting close..
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture731.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture732.jpg
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture733.jpg
I had a request to show how I made the profile template I used for the roof.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture727.jpg
Start with a profile "blank" and span the profile you need to copy.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture734.jpg
Using a compass, open up the span to insure it is wide enough to make the mark on the blank on both ends ...
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture735.jpg
Don't rotate the compass as you move it, this will make the radius larger than the original. Keep it "locked" pointed in the same direction as you glide across the roof surface, leaving the profile to cut....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture736.jpg
Cut with a band saw, jig saw, tin snips, whatever is easiest for you and most accurate. Test fit and adjust as needed.
Maddog
03-17-2014, 08:35 PM
I prefer to use a counter gauge when necessary
The shop's new apprentice started last night, so hopefully we can post project updates a bit more frequently ;)
We did some more metal bumping on the roof repair. We had some high spots to address, so Kyle held the shot bag on the inside while I used the body hammer on the outside.
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture1090.jpg
I used the blunted pick end of this hammer to address the narrow high spots. I've found it helps to more precisely locate your "strike area" by laying a guide finger next to it. Tap down the area, move to the next....
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture1091.jpg
We did have a larger high spot that made use of the hammer face, and on the bottom side Kyle held the donut dolly in place. This made short work of bringing down the high spots..
http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%203/Picture1093.jpg
Note the "graduated" markings on the roof are also on the inside to keep inside guy and outside guy on the same page with hammer and dolly alignment.
Powered by vBulletin® Version 4.2.5 Copyright © 2024 vBulletin Solutions Inc. All rights reserved.