wagon progress

[MP&C]

Well with a nice radius on the face of the glove box door skin, we now need a flat area for the lock cylinder. Since I had a piece of Polyurethane here from the care package Rich B had sent me, it seemed the right tool for the job.





The lock cylinder hole was added using a step drill for the hole and a die grinder for the notch.





A punch is used to add the needed stretch to provide the flat area..





Starting to take shape..





Some fine tuning of the detail...





The bottom flange was measured, trimmed, and folded in the Diacro press brake





The side flanges were tipped slightly in the Bead Roller.. This also gives us a nice mark to show the fold line..





Touched up with the DA





With the three flanges folded to a 90, now we'll media blast and epoxy before assembling the two halves.





This shows the tipping tool used on the side flanges.





With lock cylinder. Looks almost factory...

[55wagoncrazy]

Be VERY careful Robert......Before you know it you will have a long list of guys wanting you to build them one too. BTW Nice work!

Mikey

[MP&C]

You got that right, Mikey..

[MP&C]

Well last night's efforts saw us media blasting, hanging the next batch of small parts for epoxy primer, and general cleanup.......which has been sorely needed. So we don't have much of interest to show, so let's turn it over to Dana (the owner) who got these parts powder coated yesterday for us...

[MP&C]

Well the two weeks plus of non stop rain has finally subsided where the media blasting could commence. Got a phone call today that the car was ready to pick up.. Here it is before we loaded it up..





This is the part where you wish you had a tilt bed trailer so any media residue would be persuaded on out on the return trip home... But alas, we found a combination of using the air hose and a shop vac best to evacuate most of the media. That and about 50 or so revolutions on the rotisserie.....





Real pleased with how well it turned out... here moved into the booth and the dehumidifier energized.









We do have some pin holes that are more apparent now, so we'll get those fixed Saturday morning and see how the weather looks for priming in the afternoon..

[WagonCrazy]

It's been amazing to watch how you've brought this old wagon back to life. Thank you (again) for documenting your work for all of us to see, learn from and enjoy. Happy Memorial Day weekend!

[MP&C]

Thanks, Well, no primer just yet, while Kyle was taking care of some pin holes that
became more obvious after media blasting...










I ran across this...



























With so much widespread "issues", let's see if we can come close to
duplicating this.. Taking a paper pattern..























Here laid out on some 19 gauge AKDQ...



















Trimming...







But I always prefer a test sample first... this done on the tipping
wheel











Step dies on the Lennox add the final detail...







Need to fine tune the dimensions, but this looks close. I think I'll make up
some dies for the Lennox for better consistency on the good piece..











Should be priming soon... once the dominos stop falling.

[MP&C]

Time to make some dies for the Lennox, here fine tuning the fit..











The outside corners will get some steel added for a sharper detail in the
bends..











The 19 ga steel is a good snug fit for the band saw cuts...

















The front edge of the panel will be tipped prior to running it through the
Lennox, the tipped flange will act as a guide in the slot in the lower die..











Another test run using a straight piece of scrap

















Dimensions looking much better.











Enough practice, starting to tip the flange on the good piece.. The tipping
wheel on the bead roller bends about 30 degrees and the remaining is done
manually with the hand tipping tool..

















Flange tipped, some kick shrinking to get the right contour, and we're about
ready for the Lennox.. As Kyle was off tonight we'll wait until he returns so
we can have two people feeding this long piece through the machine..

[MP&C]

As we found with some of the practice pieces, when you try to shove metal too
much into a hole it tends to pull in from the edges.







So to fix that we'll make up a new bottom die to form the ramp fold fully,
then change back to the above die to form the step..











The down side to using phenolic is that it gives a bit where it
doesn't make sharp creases well or short reverse folds either. The initial
practice pieces wouldn't fold the step down flat, so a wrap of steel was added
to the top die to better persuade the step flat...











The upper die holder helps keep the
wrapped steel in place.







That did the trick, step is laying
down nice and flat..











The front flange hangs over just a
bit too much, some hammer action will bring it back in place. Real pleased with
how well this turned out..







Some of the practice
scraps..

[chevynut]

Pretty amazing work, Robert. You must love doing this stuff because it seems like it would have been easy to make a couple of small patches or get pieces off of a donor car and be done with it.