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MP&C
09-11-2014, 03:45 AM
Last night we turned our attention to inner fenders. We've got some items
slated to go out for powder coating, and these will get added to the pile.


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1131.jpg


The front edge that bolts outside the grille is showing remnants of water
retention...


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1132.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1133.jpg


Mountain Dew template


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1134.jpg


Bead's male die is offset to one side to match the originals.....


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1135.jpg


Bead roller was set up with a backstop die...


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1136.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1137.jpg


Skateboard wheel and "rolling" wheel used to add radiused ends....


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1138.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1139.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1140.jpg


Grabbed a suitable scrap from the pile and used the sander to make a bead
ender tool thingie, used on the treated 6x6 anvil...


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1142.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1143.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1144.jpg


Clamped and tacked....


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1145.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1146.jpg


More tonight......

carls 56 (RIP 11/24/2021)
09-11-2014, 05:32 AM
thanks for sharing Robert. :cool:

chevynut
09-11-2014, 07:47 AM
It's just amazing how you fix stuff like that and make it look so easy. I'm going to have to get me one of those skateboard wheels some day. They look like they're pretty handy and I never thought about using it to bend a radius like that. Cool stuff.

MP&C
09-11-2014, 08:53 AM
You have to "mash" the upper wheel into the skate board wheel a good bit to get the radius forming to take place, but the SB wheel still has enough give that it doesn't flatten the bead detail..

MP&C
09-11-2014, 07:54 PM
Well the Wheeling Machine finally has paint!

Napa Econo-etch primer....

http://i5.photobucket.com/albums/y167/rmccartney/Mobile%20Uploads/IMG_20140911_160851906.jpg

H/K Pavo Purple and Flo Klear. I tried playing with the camera settings to get it to capture the true color, but it just wasn't happening. It may look blue in the pic, but it's about as close to Chrysler's Plum Crazy as you can get without putting a HEMI under the hood..

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture1151.jpg

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture1153.jpg

http://i5.photobucket.com/albums/y167/rmccartney/Metalworking/Picture1154.jpg

Here's the actual color...

http://www.house-of-kolor.co.uk/images/BC10.jpg

While I was finishing up the paint on the English Wheel, Kyle stripped the driver's inner fender. This one has the same issues in the front as well as a spot up top where the flange of the fender had some rust issues we previously repaired..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1157.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1156.jpg

Looks like our same template will work here as well..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1158.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1159.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1160.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1161.jpg

And while I was trimming more rust away, Kyle was working on the passenger side learning the fine art of dressing welds...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1162.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1167.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1168.jpg

chevynut
09-11-2014, 08:20 PM
I have never felt like I was in tortal control when I use a straight die grinder. The only time I use mine is when I don't want to change tools, or I need to get into a tight spot where the 90 degree grinder won't work. I find that I have a lot more control with the 90 degree die grinder. I have 5 of them, 4 are 90 degree (Ingersol Rand) and one is straight (Harbor Freight). If you have one you might let Kyle try it with the cutoff wheel and see which he feels more comfortable with....just a suggestion

567chevys
09-14-2014, 04:21 PM
Robert your ideas and work are world class and very Amazing.


Thanks for posting the stuff on the site.

Sid

MP&C
09-17-2014, 08:09 PM
While Kyle was working on dressing some welds this evening, I took some time to planish the weld on the driver's fender eyebrow. Here's the previous.....



http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%202/Picture500.jpg


It had a noticeable dip throughout the weld seam. Here's the tool used.....



http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1196.jpg




http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1197.jpg




http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1198.jpg



The eyebrow on the passenger side was planished all by hand, and probably has a couple hours in planishing. The Watervliet planishing hammer made short work of the driver's side, it took all of five minutes time to have it in a comparable state as the passenger side...


Continuing on with more inner fender work, starting on the driver's side....


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1188.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1189.jpg


Back side, full penetration welds.....



http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1191.jpg


Staple holes for seal filled...


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1192.jpg


http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1193.jpg


Should get both these finished up Saturday morning and mocked up with the battery tray..

MP&C
09-20-2014, 02:10 PM
Here's the passenger side with the welds dressed and mocked up to the grille....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1204.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1206.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1208.jpg

While Kyle media blasted the passenger side, I did some finish work on the driver's side. We still had this up at the top to fix...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1210.jpg

A replacement was made and marked out on the inner fender..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1211.jpg

Took a reference measurement to insure any shrinking effects were properly planished out...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1213.jpg

Ice pick works well in marking the cutout pattern...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1214.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1215.jpg

Trimmed and fitted

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1217.jpg

Tacked in place...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1218.jpg

Rear side

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1219.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1224.jpg

After planishing and dressing the welds, re-checking the reference measurement....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1225.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1226.jpg

Passenger side complete....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1220.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1221.jpg

Driver's side complete.....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1228.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1229.jpg

Next task will be to assemble the battery tray and send off the goodies for powder coating.

567chevys
09-21-2014, 03:28 PM
Great work Robert ,

Thanks For sharing it :)


Sid

MP&C
09-27-2014, 03:43 PM
Today we worked on filling some holes in the battery trays. Hard to drill out a slot, so we clamped on a plate with a pilot hole to use with the Blue Point sheet metal hole cutter:

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1257.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1258.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1260.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1262.jpg

Plugs.....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1284.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1266.jpg

We tried this same repair in the corners, but the pitting was too far along and did a good job of blowing holes. So, time to back up an punt, let's make some new corners..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1267.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1275.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1276.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1277.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1279.jpg

Shrinking the tuck....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1270.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1272.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1274.jpg

New corners welded in....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1280.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1281.jpg

Some of the lines from forming were left to duplicate those from the factory...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1282.jpg

Gusset bracket added to core support....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1288.jpg

Holes located on inner fender....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1289.jpg

Stiffener brace and angle bracket bolted in....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1291.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1292.jpg

Tray bolted to the gusset, and plug welded to the angle bracket....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1300.jpg

Battery hold down brackets added....

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1303.jpg

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1304.jpg

Got a couple plug welds to grind, media blasting, and these parts are ready for powder coating!

c57heaven
09-28-2014, 08:37 AM
Thanks for your effort to educate. you make it look so easy. Also taking pics as you go isn't simply done as have to stop at each step.

NickP
09-28-2014, 09:10 AM
As always Robert, great stuff!

MP&C
09-29-2014, 06:11 AM
Thanks Nick. That's the 55 factory Air Conditioned style battery tray parts, gets the battery off the firewall...

chevynut
09-29-2014, 06:55 AM
Robert, years ago I moved my '56 battery to the radiator support area using a 57 battery tray. Worked perfectly. I assume you're doing all this work to teach metalworking, not necessarily to get the car finished as soon as possible. Some of the stuff you're doing would be easier/cheaper to just buy a new part. Thanks for the great tutorials.

MP&C
09-29-2014, 07:36 AM
I initially was making a couple sets of the brackets for Mikey Domoracki, he was going to use new reproduction trays with his.. These brackets are patterned directly from parts off a 55 AC car. He had put out feelers to see if anyone wanted some made, but I guess they are too used to paying offshore prices and those who initially expressed interest never made a peep once the price was indicated. So I only made three sets of the brackets, this being one set as Dana had wanted the battery off the firewall. On the tray, you are correct, a new repro would have been cheaper and less labor. This one had a PC finish on it, so most defects we couldn't see until it had been media blasted.. But factoring in the time to get a new one, we are all but done now and not waiting on a shipment. That happens quite a bit working on weekends in a "just get it done" fashion.. Yes, it was a good tutorial for Kyle... and those looking on now.. We will be buying the battery hold down, but it will still require an additional bracket that bolts it to the core support, per OEM style.

slowfinger
09-30-2014, 11:23 AM
Robert, Very interesting! Haven't got that far yet. Was wondering if you have advice for lengthening the pitted lower ends of the rear lower inner wheel housing where it gets welded to floor pan. We have about a 1 1/2" gap where the metal is gone. Want to save these inners on a 56 hardtop. Will be replacing the outers though. Geo.

MP&C
09-30-2014, 11:34 AM
Post up a picture....

MP&C
10-01-2014, 07:26 PM
As Kyle media blasted and otherwise prepped parts for powder coating, I turned my attention to the new grille. This looked to be a very accurate reproduction as it fit tightly in the corners exactly as the original did..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1233.jpg

In order to do some metal bumping on the grille corners and provide some clearance, which should help eliminate future front end squeaks and paint rubs, we'll need to make an anvil. This piece of pipe looks close to our templates..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1307.jpg

Unfortunately our grille shows some interference, so unless we plan on disassembly of a new grille, the anvil will need a specialized shape..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1305.jpg

After some drilling, band saw and sanding action, here are the results:

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1309.jpg

This may just work...

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1310.jpg

Working the corners.... Luckily any markings that may occur here will be covered by the surround chrome..

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1313.jpg

Test fitment shows a nice consistent gap:

http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1320.jpg

chevynut
10-01-2014, 08:35 PM
Wow, what a difference. Nice fit. Too bad the manufacturer can't make them fit right in the first place. My Gene Smith lower grille bar doesn't fit my Gene Smith stainless grille without jamming it on. It doesn't fit anything like the original parts.

MP&C
10-02-2014, 03:39 AM
Notice above the holes in this grille aren't round either...



http://i5.photobucket.com/albums/y167/rmccartney/1955%20Chevy%20Wagon%20Restoration%20Album%204/Picture1256.jpg