39 Ford Project [Archive] - Page 2 - TriFiveChevys - Trifivechevys.com is an online car club for enthusiasts of Trifive Chevy Cars and Trucks.

Custer55

04-02-2023, 07:19 PM

So with the front floorboards done other than the final trans cover piece on to the rear floorboard replacement. I will be fabricating these myself from 18 gauge cold rolled steel sheet.

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This is what the passenger side looked like with the worst of the rust cut away. Some of what is left is pretty solid but I did find some pin holes in the rib at the rear seat kick up. The drivers side was a bit better than this side but not by much.

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In the end I decided to cut out just about everything but the driveshaft tunnel. Just seemed to be easier than doing smaller patches and then trying to match the rib pattern of the original since I don't have a bead roller die that would even come close to the factory ribs.

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First step was to make a cardboard pattern with the layout for bead rolling. At first I was going to do a simple X pattern then changed my mind and did a pattern that would follow the frame x-member.

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Then I changed my mind again and did a new pattern, Hard to tell but is the silver sharpie lines.

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And now easier to see laid out on the sheet metal ready for my 1st attempt bead rolling a bigger piece like this.

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And here it is with the flange at the tunnel bent up and set in place to begin fitting it up. The actual bead rolling went pretty good for my first try at a piece this big. (used a 1/16" flanging die) Not perfect but I'm happy with the way it turned out. The only problem I had was the throat on my bead roller (Woodward Fab Super Bead Roller) not being quite deep enough so I had to flip the panel over to finish 3 out of the 4 areas.

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Once I got the seam to the front floorboards fitted up good I welded tabs to top at the front and rear so I was able to screw the panel down in the same position each time during the process of getting all the joints ready for welding.
I probably had it in and out about 20 times to get all the gaps the way I wanted them. Also located the body mount bolt holes during the process as well.

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All tacked in place ready for final welding.

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Most of the seams final welded up until my welding gas ran to low. I tried a different approach on welding up the seam on this panel, I started at the seam between the front and rear floorboards and the trans tunnel. Instead of jumping around with the welds I just started there and followed all the way around to the door post where my gas ran out. I just took my time welding a half inch or so at a time between the tacks giving plenty of cooling time as I went, always making sure I could touch the area just welded with my bare hand before continuing. It seemed to work pretty well and didn't seem as tedious as jumping around on the panel to keep things cool. The last welds I did near the door post started looking kind of bad which I was thinking might be from the metal not being clean enough but my welding gas was down to about 10 CFH of less so I will grind out that are and try welding it up again with a new gas bottle and see what happens.

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And finally here is a picture from underneath. For the most part the weld penetration is pretty good. May be a couple of spots that might need a tack weld from this side. So just need to finish the welding on this one, grind out all the welds, then repeat the process on the drivers side.
Brian :cool:

TrifiveRichard

04-03-2023, 06:03 AM

Nice job with that bead roller, Brian. Floor is looking great.

Custer55

04-03-2023, 06:18 PM

Thanks Richard.
I'm pretty happy with how it came out.

Belair-o

04-04-2023, 08:06 AM

Wow! I had no idea one could bead roll such complex areas like you did on the four areas. Very cool!

chevynut

04-07-2023, 09:24 AM

Nice job on the bead-rolling of the floor panels. I have two Mittler Brothers bead rollers and have used one of them a couple of times. I would have liked to roll some details into my rear cargo floor and inner fenders, but I got the bead roller after I made them. Also thought about having someone else do it with a different machine before I painted them but chickened out after spending so many hours building them. I would have let Robert do it. :)

Custer55

04-07-2023, 07:34 PM

Thanks guys, they are far from perfect but being floor pans which will be covered on the inside and rarely seen from underneath the main goal is the added strength which it did pretty well. One thing I need to figure out how to do is to pre-stretch the panel before rolling the pattern to eliminate the distortion it causes. It wasn't to much of an issue on these being floor pans but would be if making inner fenders or engine compartment panels and such. I watched a few videos where they use an english wheel to do the pre-stretch. I guess you could hammer and dolly the panel or use a planishing hammer too.
So now I have 2 more tools on my wish list!!

Custer55

04-09-2023, 05:38 PM

So with a new tank of welding gas I finished up welding the last seam and ground out all the welds to finish up on the passenger side floor pan.

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So with this side done time to repeat the process on the drivers side.
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Drivers side panel bead rolled, fitted up and ready to tack weld in place. I must have set the bead roller to tight doing this one as it left more of a mark around the edges than the 1st one. That's why it's good to learn on pieces that won't show unless someone crawls under the car!!

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All tacked in place with the weld tacks about a half inch apart. Once I get to this point I fill in between the tacks by doing 2 to 3 tacks at a time to fill in the gaps. I just start at one end and go all the way around making sure each weld is cool enough to touch with my bare hand before moving on to the next gap.

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Fully welded ready to grind out all the welds.

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With all the welds ground down and sanded with 80 grit it looks much better.

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So finally I have floorboards that I don't have to worry about falling through. A big improvement from the rusty mess I started with.

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One last piece to close up the last hole between the firewall and front floorboards fitted up to weld in place.
Once this is done I can work on fitting up the drivers side rocker panel I had made a while back and make one for the passenger side. It is supposed to be in the 70's here all week so with a bit of luck I can get all that done and get some epoxy primer on some of this by the end of the week.
Brian :cool:

Custer55

04-16-2023, 06:48 PM

This week I almost finished up on the floorboards. Just a few things left to call it all done.
First up was to finish up on the last piece of the firewall.

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This is the last part of the firewall in place. This one was a bit of a struggle as I fit up to the flanges on the firewall and trans tunnel at the top and bottom and fit it for butt welds on the toe kick panels. Of course the flanges on the Bitchin Products pieces needed quite a bit of tweaking to get the pieces to fit tightly together.

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View from underneath shows the fit on the flanges as well as the butt weld section lined up and tacked in place.
I wanted to get the fit on the flanges as tight as possible so they don't become a place for dirt and water to collect and cause future rust problems.

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And finally all welded up and sanded out. With a couple of coats of epoxy primer and seam sealer the joints should be good to go.

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With that done I got the drivers side rocker panel that I had made a while back fit up and screwed in place so it would be ready to get epoxy primer on both sides before welding in place for good.

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I then made up the rocker panel for the passenger side and got it fit up and screwed in place. This one turned out a bit better than the first since I had a better idea how to make it this time.

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Since our weather last week until today was in the 80's I got all the floorboards and the firewall scuffed up and cleaned up to shoot a couple of coats of epoxy primer before welding the rockers in place.

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And a better view of the firewall area. Nice thing about 30's cars with original door hinges is that it's pretty easy to pull the hinge pins and get the doors out of the way when needed. I didn't get pictures but I also got epoxy on the rockers inside and out, the master cylinder access doors and the cowl vent door backside and part of the outside of the cowl where I had welded in a new piece to repair the rust in that area.

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And today I got the drivers side rocker panel welded in place and used some spray cans to get primer and semi gloss black over the plug weld spots and the welds on each end at the door jams. So all that is left to say I am completely done with the firewall and floor pans is installing the passenger side rocker panel, and getting seam sealer around the firewall on the inside where it meets the original cowl and a few other areas that have lap weld joints. Then I can continue on to the rear seat area which I think has just a few small rust holes, and then into the trunk floor area which has major rust that will require making new panels.
Brian :cool:

BamaNomad

04-16-2023, 08:04 PM

It's looking great Brian! Way too good to consider selling when done.. :)

Custer55

04-17-2023, 04:30 PM

It's looking great Brian! Way too good to consider selling when done.. :)

Thanks Gary,
We will see about selling this one. The original intention was to get this car more sellable to help finance a project car for my wife.
Of course it has turned into more of a project than I had intended!!

Custer55

04-19-2023, 05:47 PM

So I finished up the floorboard project over the last couple of days. Got the passenger side rocker panel welded in place and a coat of paint on it. The sealed all the lap seams with the 3M drip check sealer that had come with the firewall and front floorboard kit. It was a pain in the butt to use as it was in smaller tubes so I couldn't use a caulk gun and makes a sticky mess if your not careful how you apply it. Once dried it looks like it does a nice job of sealing up the seams though. I didn't get a picture of the sealer though, maybe on the next post if I remember.

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First step was to screw the rocker panel in place and mark where I wanted to drill all the plug weld holes with a silver Sharpie. Silver Sharpie's work nice on the black painted pieces.

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All the holes (1/4") drilled and the paint ground away from the holes and on the ends where it will be welded in.
I then used a scribe to mark the location of all the holes on the floor boards below.

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Then the rocker comes back off to grind away the paint on the floorboards for the plug welds. Here I have just a few left to grind the paint off.

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And finally screwed in place ready to start welding it in for good.

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Might be hard to see in this picture but after doing all the plug welds and removing the screws, I used a countersink bit to enlarge the screw holes to make it easier to get weld penetration through both layers of metal.

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All welded in place including all the screw holes and on each end. Just need to grind out the welds and get some paint on it to be complete.

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All ground and sanded out ready for some spray can primer and semi gloss black to protect the bare metal.

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With a couple of coats of paint this phase of the project is done.
Today I started on the area below the rear seat. I wish I could have sandblasted that part of the car but that never happened so I will be using wire wheels and sandpaper to clean up that area to determine what needs to be repaired.
Stay tuned.
Brian :cool:

TrifiveRichard

04-20-2023, 03:39 PM

Making great progress, Brian. What sheet metal work do you have left, after the rear seat floors?

Custer55

04-20-2023, 05:29 PM

Thanks Richard.
After the rear seat area there is the rest of the trunk floor, the rear tail pan, and the rails around the trunk opening are not in great shape but those will be one of the last things I do. Then there is the running boards. The front fenders and hood sides have some minor rust. The grille is in pretty good shape. So I'll be busy for a while yet!!
Next project I need to find one with a lot less rust. Lol.

TrifiveRichard

04-21-2023, 05:47 AM

You’re doing a great job bringing the ‘39 back to life.

Custer55

04-26-2023, 04:52 PM

With the front & rear floorboards done time to move on to repair more rust holes. Next on the list is the area underneath the rear seat.

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The first step was to sand and wire wheel the area to figure out how much rust there was needing repair. I was hoping to only need to fill a few small holes but after poking around and getting a better look at everything decided to cut out and replace a bigger section as Indicated in the photo above,

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I decided to make the patch panel in 2 pieces to make things easier as all the shape needed on the ends would have made it pretty difficult to make it fit properly. (at least for my skill levels)

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Here I have the right end fit up so I can locate the beads to roll into the panel.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230421_161647-jpg.395428/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230421_161647-jpg.395428/
Here I have the beads added and fit up on the bottom edge of the panel. The factory beads were a lot wider than my bead roller dies could do so I just hammered in a short transition area to match them up. If this were in an area that would ever show I would have made the transition longer to make it look nicer.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230424_153700-jpg.395430/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230424_153700-jpg.395430/
All tack welded in place ready for final welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230425_143923-jpg.395432/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230425_143923-jpg.395432/
And finally all welding finished and ground out. Just need to repeat the process on the other side then start working on the trunk floor.
Brian :cool:

Custer55

05-01-2023, 05:58 PM

Finished up yesterday on the passenger side of the area under the back seat.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230427_163725-jpg.395985/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230427_163725-jpg.395985/
Here is the panel all formed up and fitted up ready to weld in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230430_150739-jpg.395986/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230430_150739-jpg.395986/
And here it is all welded up and and all the welds ground out. Far from perfect but no more rust holes so good enough for an area that will never be seen once the back seat is in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230430_155514-jpg.395987/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230430_155514-jpg.395987/
So this area will be the next challenge to repair. Major rust back here which I think was made worse when a tree fell on the car before we purchased it. The back window was broken out and even though they had duct taped a tarp over the opening a lot of water was probably still getting inside the car in this area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230430_155525-jpg.395988/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230430_155525-jpg.395988/
This brace is one of the only things back here I will be able to salvage. At least it will be easy to cut out since I won't be saving any of the metal it is attached to.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230501_140217-jpg.395989/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230501_140217-jpg.395989/
After cutting a couple pieces of 18 gauge (will be doing this in several pieces) I had a 3" wide strip left so I used it to bend up a piece that I will be able to copy the shape for the actual panels. Not going to make it exactly like the original on the backside bend to make it easier to form.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230501_154340-jpg.395990/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230501_154340-jpg.395990/
Next was laying out the pattern for bead rolling the panel to strengthen it similar to what I did on the rear floorboards. I had laid it out on the passenger side first but then realized that wouldn't work on the drivers side due to the access door needed (big rust hole) for the gas tank sending unit. Also needed to go around the little bump where the fuel filler neck goes. Once I adjusted the layout to wok around the access hole I made a sketch to layout the patterns on the metal. My 3" piece to locate the bends came in handy for this as I put a piece of masking tape over it accurately mark the front to back location of the bead rolled panels. Then I just took the tape off to get accurate measurements from the tape since I will need to do the bead rolling before making the bends in the panels.
I went to Jefferson car show on Friday and picked up some better bead rolling dies from Eastwood so hopefully those will work better than the dies I used on the rear floorboards.
Brian :cool:

WagonCrazy

05-02-2023, 11:38 AM

Outstanding progress bringing this old metal back. Keep the updates coming. We appreciate your hard work here.

BamaNomad

05-02-2023, 02:24 PM

Outstanding work... :)

bigblock

05-03-2023, 05:25 AM

I love seeing your craftsmen ship what a great job. Thanks for keeping us up to date on your progress.:)

Custer55

05-07-2023, 06:29 PM

Outstanding progress bringing this old metal back. Keep the updates coming. We appreciate your hard work here.

Outstanding work... :)

I love seeing your craftsmen ship what a great job. Thanks for keeping us up to date on your progress.:)

Thanks guys,
Will have another update soon!

Custer55

05-07-2023, 07:34 PM

So work continues to eliminate all the rust. I will have to celebrate when that day comes!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230502_095006-jpg.396561/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230502_095006-jpg.396561/
Here I have the bead rolling pattern laid out for the passenger side piece. I tried to get these pieces of 18 gauge cut as accurately and square as possible so that I would be able to make both sides the same by measuring for the bends off the edges of the sheets.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230502_103035-jpg.396562/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230502_103035-jpg.396562/
Here is the passenger side with the panels rolled in. The new Eastwood dies (on the bead roller) worked better than the dies that came with the Woodward Fab Super bead roller (on the panel) as being narrower they are much easier to see where you are going on the corners and don't mark the sheet as much.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230502_203546-jpg.396563/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230502_203546-jpg.396563/
With the first 2 bends made. I did the upper bend on my bending brake by making several small bends to get the radius I wanted. The lower bends I did on the bead roller with a 1/2" radius tipping die and a lower poly die that came in the Eastwood set. The jog on the lower bend I couldn't get to come out as well as I wanted so I just cut it out and will weld in a small piece.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_094217-jpg.396564/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_094217-jpg.396564/
Here it is with the small piece welded in place. In the upper right of the photo I had marked where I would have needed to bend in the corner to match the original shape. In the end I decided to just leave it as is vs trying to match the original shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_121226-jpg.396565/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_121226-jpg.396565/
Here I have the two bends at the top done with my test piece next to it. Again the first bend was a several small bends on the brake and the jog bend was done on the bead roller.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_124928-jpg.396566/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_124928-jpg.396566/
This is the drivers side piece with the bump for the gas tank filler neck hammered to shape. I used my nylon mallet and shot bag to get the shape needed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_141618-jpg.396567/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_141618-jpg.396567/
After some hammer and dolly work I have it looking less like a golf ball.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_154338-jpg.396568/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230504_154338-jpg.396568/
From the bottom side of the panel you can see my layout for the larger radius bends on the brake. On the 2nd panel I figured out to take the total number of bends divided by the total degrees of bend needed. Then I used my digital angle finder on the panel as I made the bends. That made it much easier to get the correct total bend and radius of the bends consistent.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230505_115344-jpg.396569/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230505_115344-jpg.396569/
Drivers side fit up and trimmed to add the small piece to weld in at the bottom bend.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230505_162936-jpg.396570/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230505_162936-jpg.396570/
And all fitted up ready to tack weld the two pieces together.
(to be continued below)

Custer55

05-07-2023, 07:42 PM

Belair-o

05-09-2023, 07:41 AM

Hi Brian,
Nice work, as always (understatement)! I appreciated the tin foil tip - I see opportunities where that will come in most handy!
Thanks, Doug

chevynut

05-09-2023, 08:36 AM

Your bead-rolling looks great. The car is really coming together and it's amazing how many new pieces are required.

I always wondered why people call aluminum foil "tin foil". It's not made of tin :p. I guess it's kinda like "pop" and "soda". I have a glob of modeling clay in my shop that I sometimes use to check clearances.

55 Rescue Dog

05-10-2023, 05:11 AM

Tin foil was made from tin, and that's what was used before aluminum foil.

chevynut

05-10-2023, 10:36 AM

Tin foil was made from tin, and that's what was used before aluminum foil.

No shit RD? You must be like another Einstein. Tin foil hasn't been in use for almost 100 years. Why call aluminum foil, made of ALUMINUM, "tin foil" when it's not made of tin?

Custer55

05-14-2023, 06:28 PM

Hi Brian,
Nice work, as always (understatement)! I appreciated the tin foil tip - I see opportunities where that will come in most handy!
Thanks, Doug[/QUOTE

Thanks Doug, The aluminum foil worked great for checking the clearance to the tank. I'm sure I'll be using that trick again.

[QUOTE=chevynut;67059]Your bead-rolling looks great. The car is really coming together and it's amazing how many new pieces are required.

Thanks Lazlo, The bead rolling is coming out pretty good except for trying to line up the spot I start and end the panels. I may have to try starting in a different spot so it's not as noticeable if they don't line up exactly. Also need to figure out a good way to pre-stretch the panel areas to minimize the distortion.

Custer55

05-14-2023, 07:43 PM

Slow but sure I am making progress on the trunk floor repairs. After getting the old flange from the original trunk floor removed I made some new flanges to install the new panels.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230509_115430-jpg.397111/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230509_115430-jpg.397111/
Here is the flange for the drivers side. Just a 1 1/2" wide piece of 18 gauge bent into a 90 and then shaped with a shrinker and stretcher. The one bend was way to much material to shrink so I first took out a pie cut, welded it back together and then fine tuned it with the shrinker. The little hump for the filler neck notch was the hardest part to get right as it needed to stretched and shrunk all in a small area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230509_135519-jpg.397112/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230509_135519-jpg.397112/
Welded in place and tied into the thicker original piece that went under the trunk floor in the body mount just to the right of the filler neck notch.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230511_151127-jpg.397117/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230511_151127-jpg.397117/
And the flange on the passenger side welded in. Here you can see the whole thicker (16 gauge or 14 gauge) original brace that went under the floor for the body mount. Before cutting out the floor at the body mounts I had welded in a strip of metal to tie in the original brace to the inner fender so nothing would move when I cut out the rusted metal in the body mount area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230511_151140-jpg.397118/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230511_151140-jpg.397118/
All the old rusty metal is gone at this point. I had to take out more than I had planned on the drivers side over the rear end.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230511_163636-jpg.397119/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230511_163636-jpg.397119/
New metal welded in place above the rear end. Because the floor is right on top of the frame in this area It would be nearly impossible to remove and replace the original weld flange without taking the body off the frame. That is not happening at this point so I just cut the old metal out as close as I could get to the inner fender and welded the new piece in as best I could. Once it's all epoxy primed and the seam is sealed up good it should be fine.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230512_163253-jpg.397121/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230512_163253-jpg.397121/
The last 8" or so section between the original metal over the top of the rear end and the new piece I made for over the gas tank area I will be making in 3 pieces. This is the first piece on the drivers side.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_095618-jpg.397122/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_095618-jpg.397122/
So yesterday morning before forming the piece for the passenger side I decided to try something to make smoothing it out easier. I had a cheap Harbor Freight air gun (think I paid $16. for it) that came with one chisel bit. I used a hole saw to cut out a 1.5" dia. piece of 3/8" flat stock, drilled out the center hole just a bit smaller than the chisel bit shank dia. and cut off the chisel bit. I then chucked the chisel bit shank in the drill press and with the drill press running filed down the shank until I was able to press the 2 together, and then welded them together. Then I put it back in the drill press and used the file and sandpaper to shape and smooth out the flat round part to make a planishing bit for the air hammer.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_095856-jpg.397123/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_095856-jpg.397123/
To try it out I hammered out a scrap piece of metal on my sand bag.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_101401-jpg.397124/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_101401-jpg.397124/
After just a few minutes of planishing It for sure smooths it out and the bit held up ok. It would be better if I knew how to heat treat the bit to make it harder and hold up better though. Also It wasn't the easiest to hold the metal over a dolly while using the air hammer with the other hand. Might have to see if I can build a stand with lower dies or just buy one.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_123622-jpg.397125/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230513_123622-jpg.397125/
And here is the end piece for the passenger side formed up and smoothed out ready to fit up and weld in place.
The air hammer worked better than using a hammer and dolly but was hard get in all the tight spots.
I got this piece welded in place and worked on the center piece today. Will have pictures of that in the next update.
Brian :cool:

chevynut

05-15-2023, 09:08 AM

Moving right along there Brian! Looks great. I gotta admit I miss doing all that fabrication work. I had more fun doing that than I have the assembly work on my car.

Custer55

05-21-2023, 07:25 PM

Moving right along there Brian! Looks great. I gotta admit I miss doing all that fabrication work. I had more fun doing that than I have the assembly work on my car.

Thanks! I agree that all the final assembly stuff can be pretty tedious at times.

Custer55

05-21-2023, 08:00 PM

I didn't get a lot done this week as I was out of town for the weekend, but here it is.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230515_103310-jpg.397644/https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230515_103310-jpg.397644/
The first thing I worked on was fitting up the center panel to finish the area behind the back seat. Originally this was a spare tire well but I just made it flat with bead rolled panels. I don't plan on having a spare tire as the car will have different front and rear tire sizes anyway. This should be a good spot to mount the battery though.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230515_183945-jpg.397645/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230515_183945-jpg.397645/
Here I have it tack welded in place. I decided to get the rear part of the trunk fabbed up and fitted before finishing the weld seams. No good reason for that, just decided I didn't feel like doing all that welding that day.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230516_125922-jpg.397646/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230516_125922-jpg.397646/
After making a cardboard pattern for the passenger side rear area I made a weld flange to fit the pattern. A couple of the sharper bends were to much metal to shrink so I made pie cuts, welded them up and then fine tuned the bends with the shrinker and stretcher.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230517_091213-jpg.397647/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230517_091213-jpg.397647/
Passenger side plug welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230517_091240-jpg.397648/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230517_091240-jpg.397648/
And the drivers side made up and plug welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230517_111348-jpg.397649/
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Then made a cardboard pattern for the passenger side rear corner which also worked for the drivers side when flipped upside down. The plan is to do this area in 3 pieces plus some small filler pieces in the corners where the the two ends and the center pieces meet.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230518_114642-jpg.397650/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230518_114642-jpg.397650/
And finally the passenger side corner piece cut out, bent up and fitted in place. I did get the drivers side fitted up as well but didn't get a picture of that. I started working on the center part but didn't get to far with it so that will be in the next update.
Brian :cool:

Belair-o

05-23-2023, 07:18 AM

Hi Brian,
What great progress you continue to make - looks great!
Regards, Doug

Custer55

05-23-2023, 04:47 PM

Hi Brian,
What great progress you continue to make - looks great!
Regards, Doug

Thanks Doug. :cool:

BamaNomad

05-23-2023, 08:27 PM

Great work as always, Brian! :)

Custer55

05-24-2023, 06:56 AM

Great work as always, Brian! :)

Thanks Gary

TrifiveRichard

05-24-2023, 02:26 PM

That’s going to be one nice, solid body when you’re done, Brian. Nice work!

Custer55

05-26-2023, 08:26 PM

That’s going to be one nice, solid body when you’re done, Brian. Nice work!
Thanks Richard, it sure will be nice to be rid of all that rust! Getting closer every day.

Custer55

05-29-2023, 07:28 PM

This week I continued working on the rearmost part of the trunk floor. I started by making a narrow sample piece to get the bends figured out for the center part.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230522_105241-jpg.398250/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230522_105241-jpg.398250/
Here I have it clamped in place on the drivers side. When I checked it on the passenger side I found a problem that needed to be fixed. The passenger side lower area of the quarter panel that I had repaired a while back didn't have quite the same shape as the drivers side which is still the original shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230522_122407-jpg.398252/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230522_122407-jpg.398252/
I made a cardboard pattern of the drivers side and used it to reshape the passenger side. I used combination of heat with the cutting torch and a tucking tool to shrink the flanges to get the correct shape. The black line on the pattern is what the shape was before fixing it.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230522_202122-jpg.398253/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230522_202122-jpg.398253/
So with that done I started on the center piece using my sample piece to layout the bends and then bead roll the panels similar to the rest of the trunk floor. Before doing the bead rolled panels I used my air hammer and planishing bit to pre-stretch the areas. It worked good to eliminate the distortion but I have to play around with air pressures and the air hammer adjustments as it was a bit to aggressive on a couple of the panels.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230523_155918-jpg.398254/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230523_155918-jpg.398254/
And with the bends made ready to fit up to the end pieces and the gas tank area panel. This one I had to bend over some square tubing as it was a couple of inches to wide for my bending brake.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230524_163008-jpg.398255/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230524_163008-jpg.398255/
All fit up with tabs welded to screw it in place I tack welded it to the end pieces hoping that I could remove and install the three pieces as a unit. Must have been my lucky day as I was able to get it out to finish the welding and small transition piece on the welding table. This made the job much easier!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230525_110158-jpg.398256/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230525_110158-jpg.398256/
Here I have the transition piece tack welded in the place on the passenger side, which turned out to be much smaller than what I was thinking it would be. If I was to do this again I would just have made the end piece slightly bigger in that area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230526_140434-jpg.398257/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230526_140434-jpg.398257/
And here is the drivers side after shaping the end and center pieces. The filler piece needed on this side was even smaller. Should have planned this out better.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230526_160325-jpg.398258/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230526_160325-jpg.398258/
All welded up and finished out. I actually used a copper backer to just weld up the gap on this side instead of making such a small filler piece.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230526_160348-jpg.398259/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230526_160348-jpg.398259/
All welded up and ready to do the final fitting.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230527_155749-jpg.398260/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230527_155749-jpg.398260/
Fitted up, screwed in place ready to final weld in place. Once everything is all welded up I think I am going to work on the trunk as that needs some tweaking to get the fit better. Then I can start on the tail pan after that is done.
Brian :cool:

TrifiveRichard

05-30-2023, 05:36 AM

It’s looking great ,Brian. Nice work!

Belair-o

05-30-2023, 07:33 AM

Shazaam! Great work, great results!

Custer55

05-30-2023, 02:35 PM

It’s looking great ,Brian. Nice work!

Shazaam! Great work, great results!

Thanks guys! :cool:

Custer55

06-05-2023, 07:09 PM

This past week I continued on welding all the trunk panels in place and finished it all up today.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230603_124721-jpg.398806/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230603_124721-jpg.398806/
All the welding done at this point and the weld seams ground out on the rearmost area. I bought some 3M cubitron 36 grit discs locally to try them out as I have heard they work well and last much longer than the cheap swap meet dics. They are not cheap but they do work nice so I ordered a box of 60 grit 2" discs online as the local auto parts store only had the 36 grit.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230603_124735-jpg.398807/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230603_124735-jpg.398807/
And the front part of the trunk floor all welded up and ready to grind out the welds. Now I remember why I put off welding up this area. It was not fun working around the braces behind the rear seat or over the the gas tank area to get in a decent position to see what I was doing. Glad that is done now!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_120847-jpg.398808/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_120847-jpg.398808/
When sanding everything out I had a slight oil can issue when I would put my weight on the highest panel over the gas tank, and a low spot at the weld seam below that. I took care of both of those issues with some torch shrinking on the weld seam between the 2 panels, and then using my shrinking disc to smooth things out a bit better. The oil can is gone now and the low spot will need less than 1/16" of filler to get it flat now, although I may not worry about it as it will be hidden behind the brace I cut out that the trunk latch will bolt to.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121442-jpg.398809/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121442-jpg.398809/
So with that done the next project will be getting the trunk to fit better and repairing the rain gutter/weather strip gutter around the trunk opening. In this picture you can see how the trunk is low to the body in the corner and high compared to the body in the middle below the rear window.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121523-jpg.398810/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121523-jpg.398810/
Another view of the fit. Probably doesn't look as bad in the pictures as it does in person.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121643-jpg.398811/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121643-jpg.398811/
And here is the rust damage in the rain gutter area that will need to be repaired. I have an idea how to make replacement pieces for this area. Hopefully it will work.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121705-jpg.398812/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_121705-jpg.398812/
Another view of the damage. This was a very bad design by Ford in this area as the weather stripping sits in this channel which basically traps any water that gets in. Not a good plan.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_164205-jpg.398813/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_164205-jpg.398813/
With the trunk removed I started on making a template of the trunk opening shape. Using a piece of 20 gauge bent into a 90 and using the stretcher / shrinker to get the correct shape. Once done this will serve 2 purposes, number one being making sure the shape of the body doesn't change when repairing the gutter area, and number two being a guide to make the trunk fit the body opening.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_164235-jpg.398814/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230605_164235-jpg.398814/
And a view of the template from the top side. Very tedious piece to make as it's very easy to over stretch or over shrink. It's getting there though and I think it will be worth the effort in the end to make sure everything fits right in the end.
Brian :cool:

Belair-o

06-06-2023, 07:37 AM

Hi Brian,
WOW! That trunk looks fabulous!
Thanks for posting all the advances you are making!
Regards, Doug

WagonCrazy

06-06-2023, 11:33 AM

That is alot of work, but we're enjoying you explaining your rationale on how you're going about it. Good for me to soak this in as I contemplate some more metal work on my Nomad.

Custer55

06-09-2023, 05:32 PM

Hi Brian,
WOW! That trunk looks fabulous!
Thanks for posting all the advances you are making!
Regards, Doug

Thanks Doug
I am pretty happy about the way it turned out

That is alot of work, but we're enjoying you explaining your rationale on how you're going about it. Good for me to soak this in as I contemplate some more metal work on my Nomad.

Thanks,
Glad you are enjoying the updates, there will be plenty more to come.

_

Custer55

06-11-2023, 05:27 PM

This week I worked on the trunk gutter in the hinge area. I wanted this to be solidly repaired before trying to get the trunk lid to fit better.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230606_103155-jpg.399183/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230606_103155-jpg.399183/
I had intended to make the template to go from one side of the trunk opening to the other but decided to just make it to the middle for now since I would be repairing the gutter area in 3 pieces anyway.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230607_185524-jpg.399184/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230607_185524-jpg.399184/
To start with I cut a piece of 18 gauge to width and then bent it to match the dimensions of the original gutters.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230606_161837-jpg.399185/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230606_161837-jpg.399185/
Then using my stretcher and shrinker I formed it to fit the shape of the left side trunk opening. I left the piece a little big on the top edge to make it easier to tell when the shape was correct. I also used the trunk hinges to help hold the new gutter piece in the correct position.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230607_112447-jpg.399186/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230607_112447-jpg.399186/
With the shape pretty good I trimmed about and 1/8" off the top of the replacement piece and clamped it in place on the trunk hinge and then scribed a line on the trunk opening to trim back to so I would have a nice tight fit for welding it in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230607_120506-jpg.399189/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230607_120506-jpg.399189/
And tack welded in place. After checking with my template nothing had moved at all so I decided to do the other side without making the template for the passenger side.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230608_125938-jpg.399190/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230608_125938-jpg.399190/
Passenger side formed and fitted up to weld in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230608_190011-jpg.399191/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230608_190011-jpg.399191/
Center piece formed up and clamped in place ready to tack weld in place. This was by far the easiest of the 3 to make as it just has a slight curve to it.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230608_201828-jpg.399192/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230608_201828-jpg.399192/
All tack welded in place.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230609_121550-jpg.399193/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230609_121550-jpg.399193/
And finally with all the tack welds ground flat and the joints between the 3 pieces fully welded and ground out. Also at this point I have the original trunk hinge bolts back in the new gutter to hold everything solidly in place to fit up the trunk lid. I still need to finish the weld seam at the body to gutter. The plan is to do this after the gutters have been replaced on the sides and at the bottom trunk opening. Hopefully there will be less chance of distortion with everything tack welded in place every half inch or so before fully welding any of the seams.
Brian :cool:

BamaNomad

06-11-2023, 06:31 PM

*Adding "Metal Master" to the list of Brian's accomplishments!! :)

bigblock

06-12-2023, 05:50 AM

Amen:)

Custer55

06-19-2023, 05:24 PM

*Adding "Metal Master" to the list of Brian's accomplishments!! :)

Amen:)

Thanks guys, far from being a metal master though, but I'm learning as I go.

Custer55

06-19-2023, 06:33 PM

So with the top gutter of the trunk opening securely tack welded in place my next project was to get the trunk lid to fit the opening as best I could.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230610_152618-jpg.399769/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230610_152618-jpg.399769/
With the trunk lid back on a shimmed and adjusted I marked up where it needed adjustments to get the fit better.
It was low on the drivers side corner and high in the middle between the tape marks which is where the hinges fall. The right hand corner was pretty good other than the gaps being too tight, which will be easy enough to adjust later by grinding the edges of the trunk, and then welding the edges up and re-grinding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230612_124448-jpg.399773/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230612_124448-jpg.399773/
I then made a new profile gauge for the trunk opening as the one half I had made before was hard to get the fit just right. On this one I made a flat piece to fit the opening pretty close then welded another flat piece on top of that to form a T shape. I was then able to get it to fit a lot better by shrinking, stretching and filing and grinding the edge.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230613_161858-jpg.399774/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230613_161858-jpg.399774/
Then with the aid of the profile gauge I got the shape better by slicing the trunk lid inner structure and welding it back together to reshape it to match the trunk opening. A couple of spots on the drivers side outside of the hinge pad I sliced and added a thin piece of metal. I also welded the shims needed on the upper bolt holes in place to make installation easier.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230613_204237-jpg.399775/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230613_204237-jpg.399775/
With the trunk lid back in place the fit is pretty good now. May still just need a bit of an adjustment on the drivers side upper corner.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_113353-jpg.399776/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_113353-jpg.399776/
So next was to make the new gutters for the sides of the trunk opening. This shot is before stretching and shrinking to fit the curve of the opening.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_120107-jpg.399778/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_120107-jpg.399778/
After forming to shape but still needing to make the final bend.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_111721-jpg.399779/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_111721-jpg.399779/
I made this tool for making the final bend. Just a piece of round bar with a slot cut in it to the depth of the final bend (5/16" in this case). I ended up clamping the tool in a vise and then made the bend by putting the piece in the slot and used a combination of bending by hand and tapping it down with a dead blow rubber mallet a bit at a time.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_111652-jpg.399780/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_111652-jpg.399780/
A shot of a finished piece, the tool and a piece needing forming and the final bend.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_163410-jpg.399781/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_163410-jpg.399781/
Here is the passenger side top piece fitted up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_112113-jpg.399782/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230615_112113-jpg.399782/
And the drivers side formed up ready for final fitting and tack welding in place which I did get done today but I didn't get a picture of yet. So the next task will be getting the lower pieces of each trunk side formed, fitted and tack welded in place before starting on the tail pan.
Brian :cool:

BamaNomad

06-19-2023, 08:51 PM

You're doing fantastic Brian... much better than some who DO call themselves metal masters.. :)

TrifiveRichard

06-20-2023, 05:13 AM

That’s looking really nice, Brian. Great job!

Custer55

06-20-2023, 06:14 PM

You're doing fantastic Brian... much better than some who DO call themselves metal masters.. :)

Thanks Gary

That’s looking really nice, Brian. Great job!

Thanks Richard

WagonCrazy

06-21-2023, 09:36 AM

Its great to watch your progress. I have limited metal shaping skills, and limited tools for it, but I see you doing this old jalopy a great service bringing it back from the dead! Gonna be great when you finally get to drive it around. Your sweat equity will be appreciated by many, most importantly YOU.
Carry on!

Custer55

06-21-2023, 04:57 PM

Custer55

07-11-2023, 09:06 PM

No progress to report on the 39 yet as I have been pretty busy on other things since the middle of June. I went to the Indy car race at Road America on fathers day with my son and my brother. The week after that was our annual trip to Minnesota for "Back to the 50's" car show. Great show as always even with the really hot weather on Friday and a few rain showers on Friday, Saturday and the ride home on Sunday. Not gonna complain about a bit of rain though as it was super dry out there. I have never seen it that dry in the 25 plus years we have been going out there.
Then the week after getting back home my wife and I were volunteering at the US Senior Open at Sentry World all of the following week. Overall it was a pretty cool experience having a major event like that in our small town. Stevens Point has a population of about 26,000, The Point, Whiting, and Plover area is about 40,000.
Then just a few days after that was the Iola Car Show & Swap Meet this past weekend. The weather for Iola was about as perfect as you could ask for with highs in the Mid to upper 70's and partly cloudy all weekend.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230709_150434-jpg.401649/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230709_150434-jpg.401649/
Early Thursday morning at Iola I bought this at the swap meet. Pretty good deal as it is in nice shape and cost me less than half of what they are new. Should come in handy for making panels once I get the hang of using it.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230709_160739-jpg.401650/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230709_160739-jpg.401650/
The dies it came with aren't the greatest but after some filing and sanding with 80 grit and working up to 400 grit they look much better. The one on the right (2" radius die) is the way they all looked before sanding and polishing.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_191514-jpg.401651/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_191514-jpg.401651/
Here is all of the lower dies (1", 2" and 3" radius) sanded and polished out. The 2" radius die actually almost had a bit of a point in the middle but I have the shape much better now.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230709_150654-jpg.401653/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230709_150654-jpg.401653/
Here is a couple of test pieces I did with it. I will have to play around with air pressures and the regulator settings (it has a small regulator at the air hammer) but it seems to work pretty well for what it is.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_141832-jpg.401654/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_141832-jpg.401654/
Since the included dies will be good for tight curves but not so much for low crown areas I decided to try to make a die with a bigger radius. I found some pieces on my scrap pile that will work good enough to give it a try.
These will be welded together and then shaped, sanded and polished out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_153146-jpg.401655/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_153146-jpg.401655/
Welded together and ready for sanding and polishing. Shooting for a 6" to 8" radius based on what I will need to make the new rear tail pan.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_191447-jpg.401656/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230710_191447-jpg.401656/
Well my first attempt was a failure. It worked good for about a minute before it broke apart. Obviously not welded together very well. I had only ground a V on the top of the inner post and not the outer ring so there was not near enough weld and I didn't weld the bottom of the outer ring to the post at all.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230711_181323-jpg.401657/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230711_181323-jpg.401657/
So this time I made sure to grind out the outer ring at the top and bottom so there should be a good strong weld to hold the outer ring to the post. If this doesn't work I will see if I can find a machine shop to make me some blanks out of a single piece of steel. A small lathe would make this a pretty simple project. Not in the budget at this time but someday I will have to get one.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230711_182240-jpg.401658/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230711_182240-jpg.401658/
And finally with a 6" radius template on top of the blank it won't take much grinding to get it to a 6" radius. Just from grinding out the welds trying to keep it flat it's already close to a 10" or so radius.
Brian :cool:

BamaNomad

07-12-2023, 05:37 AM

Brian, with that new tool at your disposal your outstanding work of the past will be even better! :)

Custer55

07-20-2023, 06:39 PM

So after sanding and polishing the 6" radius die and trying it out I can finally start getting some work done on the 39 again.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230712_113147-jpg.402419/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230712_113147-jpg.402419/
Still not welded as well as I would like but at least this time it didn't break and it worked decent too.
When I need dies with a different radius I will most likely find someone to make a blank on a lathe though.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230714_160304-jpg.402420/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230714_160304-jpg.402420/
Taking up where I left off a while back, making the bottom portion of the side trunk gutter pieces. Bent to a 90 and then formed to fit the curvature of the trunk, this one is ready to make the last bend. This one I fit to the trunk lid as well as the quarter panel since the quarter panel had some damage at the lower end.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_123528-jpg.402421/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_123528-jpg.402421/
With the 2nd bend made and fitted up for tack welding in place. The duct tape (T-Rex tape in this case) works well to hold pieces like this in place for tack welding as there is no good place to clamp it once it is fit up. I start tack welding at the joint to the upper piece and work my way down to the bottom with tacks about a half inch apart.
With a few tack welds in place I can remove the tape as I go along then.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_160723-jpg.402423/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_160723-jpg.402423/
All tack welded in place and tack welds ground flat.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_160636-jpg.402424/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_160636-jpg.402424/
With the trunk closed to check the fit. Looks good enough for me. I did check the fit before tack welding it in place as well.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_160648-jpg.402427/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230717_160648-jpg.402427/
Another view of the gap to the quarter panel. It's a little bit wider towards the top but not too bad.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230719_103312-jpg.402428/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230719_103312-jpg.402428/
Passenger side piece formed and fitted up for tack welding in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230720_105538-jpg.402429/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230720_105538-jpg.402429/
Tack welded in place with the seam between the upper and lower pieces fully welded and ground out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230720_105821-jpg.402430/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230720_105821-jpg.402430/
With everything but the tail pan tacked in place the fit all the way around the trunk to the body is pretty good. I have a couple of spots on the trunk lid that I need to grind and re-weld the edges to get the gaps a little better yet, but overall it looks good. Much better than it was for sure. So the next project will be cutting out the tail pan to build a new one. We shall see how well that goes!!
Brian :cool:

BamaNomad

07-26-2023, 07:07 PM

It's looking better and better Brian! :)

Custer55

07-27-2023, 07:57 PM

It's looking better and better Brian! :)

Thanks Gary

Custer55

07-30-2023, 06:12 PM

This past week or so I got started on my attempt to make a new tail pan. The first step in that process was to get rid of the old rusty one.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_114334-jpg.403308/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_114334-jpg.403308/
After laying out a grid on the old tail pan and making a few patterns of the shape as best as I could tell with what was left of it I got it removed.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_105353-jpg.403310/https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_105353-jpg.403310/
Before starting on the new tail pan I got the quarter panel lower section flange straightened out and plug welded to the trunk area I had replaced previously.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_105341-jpg.403311/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_105341-jpg.403311/
On the passenger side I had to add a small section to the flange. When I had repaired the lower quarter panel in this area a while back I didn't make it go up high enough.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_112755-jpg.403312/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230721_112755-jpg.403312/
All welded up and good to go.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230723_134051-jpg.403313/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230723_134051-jpg.403313/
Next up was making a wooden buck to use as a guide for making the new tail pan. I had a big enough piece of 3/4" plywood on hand so I figured that would work as well as anything. At this point assembled with screws to fit the opening so I could mark out the shape of the trunk and quarter panels on it, and then take it apart to cut them to shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230725_162903-jpg.403315/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230725_162903-jpg.403315/
Here I have all the outer pieces cut and sanded to shape. The bottom piece is and educated guess as there wasn't much left of the original to go by. Not a big deal for me as it doesn't need to be exactly as original, it just needs to look good.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230727_144455-jpg.403316/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230727_144455-jpg.403316/
And with ribs added in the middle ready to sand the bottom board to match the shape of the ribs at the bottom.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_104808-jpg.403319/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_104808-jpg.403319/
With the buck back out I laid the original tail pan over the buck to see how it fits. I looks reasonably close to what is left of the original.
(to be continued below)

Custer55

07-30-2023, 06:18 PM

continued below

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_102539-jpg.403320/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_102539-jpg.403320/
I then taped a piece of paper on the buck to get a better idea of what the finished piece will look like.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_102555-jpg.403321/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_102555-jpg.403321/
And another view, looks like it should work ok to me.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_104402-jpg.403322/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_104402-jpg.403322/
And the paper can be used as a pattern to cut out the piece of metal. I will be doing this in 3 sections to simplify the process somewhat.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_142920-jpg.403324/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230728_142920-jpg.403324/
And the last step for making the buck was adding windows to the frame work to make it easier to tell if the metal is shaped the same as the buck. Building this thing was a good reminder of why I don't care for doing wood working.
Saw dust and wood sanding dust are one of my least favorite things for sure!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230730_133951-jpg.403325/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230730_133951-jpg.403325/
Starting with the middle piece figuring it should be a little easier than the ends to form up. This is after a few hours of shaping the curve top to bottom and shrinking the outer edges and hammering the middle over a sand bag to to stretch it a bit to form the shape left to right. Then using my new planishing hammer on the right half to smooth it back out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230730_150758-jpg.403326/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230730_150758-jpg.403326/
After smoothing it out better the shape is getting there. At this point I was ready to bend over the bottom flange and trim it to size.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230730_150817-jpg.403327/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230730_150817-jpg.403327/
At this point it seems to lay on the buck pretty well but I can tell in this picture that I need to shrink a couple of spots on the lower outer ends to get it to fit better yet. Not sure how to accomplish that yet but I'll have to figure it out.
Stay tuned.
Brian :cool:

BamaNomad

07-30-2023, 07:48 PM

Wow Brian.... you're moving quickly onto the 'big boy metal working' ranks.... My compliments!

busterwivell

07-31-2023, 04:32 AM

I continue to be amazed!

Troy

07-31-2023, 10:04 AM

Man you do good work, I wish I could do that kind of stuff!!!! I thought the wooden one looked good!!!:D

Custer55

07-31-2023, 05:34 PM

Wow Brian.... you're moving quickly onto the 'big boy metal working' ranks.... My compliments!

Thanks Gary, Some days are quite a struggle but I am learning as I go.

I continue to be amazed!

Thanks, Glad you are following my learning process.

Man you do good work, I wish I could do that kind of stuff!!!! I thought the wooden one looked good!!!:D

Thanks Troy, You would be surprised what you can do if you give it a try. I have been learning a lot by watching metal shaping videos on YouTube
Brian

Custer55

07-31-2023, 06:12 PM

A quick update on what I got done today on the center piece of the tail pan.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_095826-jpg.403406/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_095826-jpg.403406/
Here is a shot of the gap to the wood buck at the ends of the center piece.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_095849-jpg.403407/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_095849-jpg.403407/
Compared to the fit on one of the center ribs, so some adjustment at the ends is going to be needed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_100022-jpg.403408/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_100022-jpg.403408/
The first thing I did was put a guide coat on the panel with a wide magic marker and then sand it off with a long board sander to highlight the high spots that will need shrinking.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_112725-jpg.403409/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_112725-jpg.403409/
After doing heat shrinks with the welding torch and then more tuck shrinks on the edges then shape is better now.
I think the tuck shrinks on the edges were not enough initially as they don't reach far enough in to shrink everything that needed to be. I may have to re-watch some more videos to see if there is a better way to do this.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_125525-jpg.403410/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_125525-jpg.403410/
Before planishing the panel out again I used a shrinking disc to smooth out the areas that I did the heat shrinking.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_161327-jpg.403411/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_161327-jpg.403411/
After more planishing to smooth things out again and doing some re-shaping it is looking much better and fits the buck pretty well now. Not perfect by any means but it won't need more than a skim coat of filler at this point so I am happy with it.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_161751-jpg.403412/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230731_161751-jpg.403412/
With the panel clamped in place it looks like it should work ok. So time to move on to attempt making the end pieces.
Brian :cool:

Belair-o

08-01-2023, 07:47 AM

Hi Brian,
What a great transformation! Very nice work - thanks for showing the methodology!
Regards, Doug

bigblock

08-01-2023, 08:01 AM

Very Nice!!!

Custer55

08-04-2023, 06:31 PM

Hi Brian,
What a great transformation! Very nice work - thanks for showing the methodology!
Regards, Doug

Very Nice!!!

Thanks guys!

Custer55

08-04-2023, 07:26 PM

So with the center part looking pretty close time to start working on the ends. These will need more shaping as they will need a tighter curve at the ends where they meet the quarter panels.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_110317-jpg.403694/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_110317-jpg.403694/The first step was to make a pattern with the needed flanges added and then cut a piece of 18 gauge to match.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_111539-jpg.403695/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_111539-jpg.403695/Then made a bend on the brake for the top flange at the trunk opening. This will eventually get shaped to match the trunk on the shrinker/stretcher.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_112722-jpg.403696/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_112722-jpg.403696/Then shaped the panel to match the curve of the buck from top to bottom. I mostly did this by bending it over my upper leg and the buck itself. Anything that is somewhat round will work.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_123856-jpg.403697/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_123856-jpg.403697/Then I did a combination of tuck shrinks, shrinks with the shrinker/stretcher, hammer and dolly work and hammering it over the buck itself. At this point I had done some work on it with the planishing hammer with a 1" radius die to smooth it out as well.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_155118-jpg.403698/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230801_155118-jpg.403698/This is after using the planishing hammer to shape the balance of the piece to better match the buck and transition into the center section of the tail pan. I did end up slicing the upper and lower corners to make them fit the contour of the wooden buck better.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230802_102802-jpg.403699/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230802_102802-jpg.403699/With the shape looking pretty close I screwed the end and center together to check the fit on the car.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230802_103419-jpg.403700/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230802_103419-jpg.403700/A quick test fit shows I should be able to make it work. So on to making the left hand end.

(continued below)

Custer55

08-04-2023, 07:30 PM

So time to repeat the process on the other side.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230803_192321-jpg.403701/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230803_192321-jpg.403701/
I'll skip some of the initial process as it is the same as the right hand piece. This shot shows how the flange that meets the trunk lid was shrunk to match the buck. The profile gauge is a match to the top edge of the piece where it meets the trunk lid. Obviously it doesn't match lower down on the piece. To correct this I used the grid pattern I had drawn out and used the planishing hammer with a 3" radius die to re-shape/stretch the low area up where it needed to be. Then I used the 6" radius die that I made to smooth it all out again.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230803_195735-jpg.403703/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230803_195735-jpg.403703/
Here is a shot after planishing it out to re-shape it. It doesn't match the profile gauge exactly but I think that is ok because the tail pan has less of a curve to it at the bottom than it does where it meets the trunk.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230804_135033-jpg.403704/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230804_135033-jpg.403704/
Here I have all three pieces screwed together to make sure it will fit when it's all welded together. Looks pretty close to me.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230804_145050-jpg.403705/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230804_145050-jpg.403705/
After taking the pieces apart I put the two ends next to each other to see if they were shaped reasonably close to each other. This is after a bit more hammer and dolly work, and smoothing on the planishing hammer.
I think they are good at this point since they will be about 32" apart from each other on the car.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230804_161801-jpg.403707/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230804_161801-jpg.403707/
Here is where I left off today. I had made all the pieces with a 2" or so overlap, so I could trim to fit for welding with a nice tight gap. After just a bit more trimming I should be ready to start tack welding them together. I plan to tack weld them right on the buck so I did make sure the weld seam won't be right over the ribs of the buck. Don't want anything starting on fire!!
Brian :cool:

TrifiveRichard

08-05-2023, 05:02 AM

Looking great Brian. You’ll be done with the metal work soon!

Custer55

08-05-2023, 08:03 PM

Looking great Brian. You’ll be done with the metal work soon!

Thanks Richard, I hope it will be done soon. Once the back of the car is done it will just be the front fenders, hood sides, and running boards that need work.

Custer55

08-10-2023, 09:08 PM

After a bit more fitting of the 3 pieces of the tail pan it was time to weld them together. I decided against tack welding them together on the buck, as I figured if it all lined up correctly on the buck with tight gaps there was no need to leave the pieces on the buck to weld them together.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230806_140604-jpg.404345/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230806_140604-jpg.404345/
Here I have one end tack welded in place and starting on the other end. I started at the top and worked my way down with tacks about a half inch apart, trying to keep things as lined up as possible.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230806_145607-jpg.404346/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230806_145607-jpg.404346/
All tack welded together and over the buck again to check the fit.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230806_154348-jpg.404347/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230806_154348-jpg.404347/
And on the car again to double check the fit before fully welding the seams.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230807_125210-jpg.404348/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230807_125210-jpg.404348/
After grinding all the tack welds flat inside and out I started the process of fully welding the seams. I used a little different process that what I usually do on this to make sure I didn't get impatient and warp anything to much.
Started at the top and did three tacks at once on each seam, then lightly hammered the welds to stretch the tacks out a bit. Then I ground the welds inside and out before doing the next set of tack welds. It was a bit more work doing it this way but the weld warpage was minimal so it was worth taking the extra time.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230807_145246-jpg.404350/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230807_145246-jpg.404350/
Here is a shot of the weld on the backside of the weld seam, so I know I was getting the seam fully penetrated which is nice!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230807_183931-jpg.404351/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230807_183931-jpg.404351/
And another test fit after all the welding was done.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230808_110244-jpg.404352/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230808_110244-jpg.404352/
To get the weld seams and a few low spots smoothed out better I put a light coat of spray can primer on the panel.
Then went through the process of block sanding the primer and then planishing the low spots until the panel looked and felt better. I am about half done at this point.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230808_141212-jpg.404353/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230808_141212-jpg.404353/
Looking pretty good at this point so time to punch some plug weld holes, get it lined up on the car again and clamp and screw it in place for final welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230808_161923-jpg.404354/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230808_161923-jpg.404354/
Finally welded in for keeps. I will still need to do some work on the trunk lid to get the gaps a little better but overall I am happy with the way it turned out. Not bad for my first attempt at making a complete piece like this.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230809_180517-jpg.404355/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230809_180517-jpg.404355/
And a view from the inside. Next I need to form up and weld the weather strip channel to the the tail pan like I did on the rest of the trunk opening. Then the original factory braces that I removed will have to be replaced to call this a done deal but it is getting close. Sure is nice to not have any rust holes back there anymore!!
Brian :cool:

Troy

08-11-2023, 09:22 AM

Wow she's got a nice booty!!:)

Belair-o

08-11-2023, 03:32 PM

Sweet! Nice job!

bigblock

08-12-2023, 06:59 AM

Really nice work:)

Custer55

08-14-2023, 06:29 PM

Wow she's got a nice booty!!:)

Really nice work:)

Sweet! Nice job!

Thanks guys!! :cool:

Custer55

08-14-2023, 07:23 PM

The next step in the tail pan project was to make the weather strip channel as I had done around the rest or the trunk opening. Making this one is similar to the one at the top of the trunk opening, other than being shorter so I was able to make it in just 2 pieces.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230810_160608-jpg.404759/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230810_160608-jpg.404759/
Here I have the left hand side formed to shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_114950-jpg.404760/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_114950-jpg.404760/
And the right hand side formed and fitted up to tack weld in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_134847-jpg.404762/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_134847-jpg.404762/
And tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_161334-jpg.404763/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_161334-jpg.404763/
And with the left side fitted up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_130544-jpg.404766/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_130544-jpg.404766/
So with that done my next project was to get the trunk prop rod slide bracket repaired and back in place so I don't have to use an old light stand to hold the trunk open anymore. It was kind of a mess as I had to cut it out in 2 pieces to get the quarter panel back in shape. At this point I had done quite a bit of work to straighten it, re-shape it to the trunk opening, and tack weld the 2 pieces back together. In this shot I have it held in place with a couple of sheet metal screws to make sure it would work properly, which it did.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_151748-jpg.404770/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_151748-jpg.404770/
All welded up ready to weld it back in place for keeps.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_151734-jpg.404771/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_151734-jpg.404771/
Before welding it back in place though I had to weld the original corner braces back in place as the prop rod slide bracket overlaps the corner brace by a bit on the left hand side.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_161211-jpg.404772/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230812_161211-jpg.404772/
And welded back in place, so now I can have the trunk stay open on it's own!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_161312-jpg.404774/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230811_161312-jpg.404774/
Next will be getting the original trunk to tail pan brace tuned up and replaced. Here it still needs the remnants of the original tail pan and trunk floor removed so it can be fitted up to the new panels. Everything seems pretty strong without it but it needs to be in place to hold the trunk latch striker plate.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230813_150216-jpg.404776/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230813_150216-jpg.404776/
Here all the remnants of the tail pan and trunk floor have been removed from the bracket, and fitted up to match the new shape of the trunk floor as I did not make that the same as it was originally. Still needs to be sandblasted before it gets welded in. And I will have to search for the trunk latch and striker plate to make sure it is positioned on the tail pan end so that the trunk latch will work properly.
Brian :cool:

Belair-o

08-20-2023, 08:02 AM

Hi Brian,
Never having previously seen the tail pan configuration on the '39 Ford sedans, it seems like a useful space, but less so when the brace is welded in place. I guess it was a place for stowing misc. smaller items?
Thanks, Doug

Custer55

08-20-2023, 10:39 AM

Yes, as I think it was originally called the tool box area. Would be a good place to put a tool bag and car cleaning items and such.

Custer55

08-21-2023, 07:09 PM

After a few adjustments I got the trunk to latch properly so I got the brace that holds the trunk latch permanently welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230815_130401-jpg.405426/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230815_130401-jpg.405426/
Here it is sandblasted and welded in place. I think I need to get a new sandblast gun for my cabinet (Harbor Freight) as it seemed to take way to long to get this cleaned up.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230816_123958-jpg.405427/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230816_123958-jpg.405427/
With that done time to fully weld the seams around the trunk opening. I did these like usual stitching together three tacks at a time, wire wheel them clean, then letting it cool before doing another set of 3 tacks.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230817_113710-jpg.405429/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230817_113710-jpg.405429/
Then grinding the welds smooth and using a hand file to get the edge of the opening to look right.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230818_151029-jpg.405433/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230818_151029-jpg.405433/
All the seams fully welded and the left and bottom seams finished out. A tedious process as I can do about 18" of weld seam per hour just for the welding. All the way around the trunk opening is about 140" and then it all needs to ground out to finish the welds.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230818_162938-jpg.405434/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230818_162938-jpg.405434/
With the trunk closed to check the fit again. Looks the same as before welding the seams so nothing moved much if at all.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230821_141303-jpg.405435/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230821_141303-jpg.405435/
A close up shot of the weld seam on the back side so I know that I am getting excellent weld penetration on the inside of the seams.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230821_141435-jpg.405436/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230821_141435-jpg.405436/
Here all the seams are all finished out. A big improvement over the rusty mess it was when I started.
Next will be some work on the trunk lid itself to get the gaps better. There are a couple of spots that the trunk lid needs to be ground back where the gaps a bit tight and the trunk lid to tail pan gap need to be closed up some.
Once that is done I want to get epoxy primer on all the bare metal before moving on to working on the front fenders.
Brian :cool:

BamaNomad

08-22-2023, 02:54 PM

That's going to be a beauty once it's all in one color.. even if it's just primer.. :)

Custer55

08-27-2023, 05:19 PM

This week I fixed the gaps on a couple of places on the trunk lid. Mostly just in the upper right hand corner and the trunk lid to tail pan gap.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_104905-jpg.405954/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_104905-jpg.405954/In this shot I had already ground the edge of the trunk between the sharpie mark and the upper corner to get the gap where I wanted.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_113946-jpg.405955/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_113946-jpg.405955/Next I welded up the edge as grinding it back created a split between the outer skin and the inner bracing about 1/4 of the way down and made it who knows how thin the rest of the way. So to be safe I welded it up all the way to where I started grinding the edge.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_151050-jpg.405956/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_151050-jpg.405956/Then I ground the welds flat to the outer and inner skin so I could then grind the edge again get the gap right without worrying about making any thin spots.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_161005-jpg.405957/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_161005-jpg.405957/And all ground back to get a nice gap again.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_161254-jpg.405958/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_161254-jpg.405958/And the last area to fix the gaps is the trunk to tail pan. The gap is good on the ends but everywhere in between it is to wide and inconsistent. Probably a combination of not getting the tail pan made quite right and the previous trunk repair not being done as good as it should have been.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_202123-jpg.405959/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230822_202123-jpg.405959/Since moving the tail pan at this point is not a good option I decided to weld an 1/8" rod to the bottom edge of the trunk to get the gap better.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230823_121219-jpg.405960/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230823_121219-jpg.405960/Here the rod is fully welded to the trunk on the outside. Still need to weld it on the inside before grinding the gap to fit.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230823_121433-jpg.405961/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230823_121433-jpg.405961/A shot of the inside before welding. Welding this up solid was a pain because it was pretty much an overhead weld. I didn't want to take the trunk off and chance it wouldn't end up in the exact same position until I had all the gaps fixed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230824_130106-jpg.405962/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230824_130106-jpg.405962/All ground an filed to fit like it should now. So now finally I can get everything prepped to get a couple coats of epoxy primer on all the bare metal.
Brian :cool:

TrifiveRichard

08-28-2023, 02:04 PM

Looking good, as usual Brian.

bigblock

08-29-2023, 06:19 AM

Really nice work!!!!

BamaNomad

08-29-2023, 02:14 PM

I am looking forward to seeing it all one color, after all your metal work!! :)

Custer55

08-31-2023, 04:56 PM

Looking good, as usual Brian.
Thanks Richard

Really nice work!!!!
Thanks much!!

I am looking forward to seeing it all one color, after all your metal work!! :)
Thanks Gary, Me too!! hopefully that will be soon.

Custer55

09-02-2023, 06:37 PM

This past week I spent prepping for epoxy primer over most of the bare metal areas. Not sure what I am going to to with the bottom of the car yet. I don't have a lift so using a spray gun underneath the car won't be a good option, so I will have to try something I can apply with a brush. I may try my epoxy primer (Tamco DTA) without any reducer and see how it works applying it with a brush.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230827_100403-jpg.406520/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230827_100403-jpg.406520/
The first thing I worked on was putting some fiberglass reinforced bondo on a few areas that I didn't get the metal smoothed out real well. This lower section that I had patched the trunk was one of them.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230829_124442-jpg.406523/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230829_124442-jpg.406523/
Also did some around the trunk area where I welded in the new gutter to fill in a few weld voids, and the top edge of the tail pan where I had made some adjustments getting it to fit the trunk shape better. At this point everything was sanded and ready for epoxy. The biggest pain was getting all the weld spatter removed. I should try to cover things up to keep the spatter off things as much as possible as it wasn't fun to get it all off.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230829_124501-jpg.406524/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230829_124501-jpg.406524/
And a coupe of spots on the trunk inner structure where new metal had been welded in.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_092814-jpg.406526/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_092814-jpg.406526/
A couple of coats of epoxy on the inside of the trunk, just doing one side at a time on the trunk lid as I don't have a good place to hang it up to do both sides at once right now.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_093022-jpg.406527/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_093022-jpg.406527/
And on the new trunk floor and trunk opening as well as the tail pan and lower quarter panels. Also got a couple coats on the inner fenders inside the trunk so it all looks nicer than it did before. The primer looks more gray in some of the pictures but it is just the lighting at the time, as it is all black.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_093049-jpg.406528/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_093049-jpg.406528/
Another view from directly behind the car.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_200054-jpg.406529/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230830_200054-jpg.406529/
With that done I prepped the cowl and firewall to get all of that covered in epoxy primer as well.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230901_130254-jpg.406530/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230901_130254-jpg.406530/
Looking much better with no more bare metal showing.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230901_130231-jpg.406531/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230901_130231-jpg.406531/
And finally primer on the outside of the trunk lid. This ended up with 3 coats as I mixed a bit too much primer, so no sense letting it go to waste. Also got the outside of the cowl vent door sprayed but didn't get a picture of that.
Next will be getting the doors and trunk back on so it will will look like a whole car again other than the front clip. That will be the next project to tackle!!
Brian :cool:

busterwivell

09-03-2023, 06:37 AM

Amazing what you've done, Brian. You should be very proud.

Belair-o

09-03-2023, 01:55 PM

Sweet! That is really looking great!

chevynut

09-04-2023, 08:46 AM

It's a little late but my painter has been painting high-end cars for decades and he uses only one product to prep his cars. He uses a product called "All-U-Need" by Clausen. It's a zinc-enriched waterproof high build polyester primer. He sprays it thick on bare metal, blocks it, and sprays more and keeps blocking it until he gets the body straight. He probably uses some filler if needed but I think his metalwork is good enough that he doesn't need it much. He doesn't even worry about having bare metal spots. Then he shoots a coat of good epoxy sealer and paints the car. I wish I'd known about this stuff before I started prepping my Nomad for paint because it's a lot simpler and probably better and far less expensive process than what I did (PPG DPLF, Slicksand, PPG K-36). He says he's never had problems with it and he paints million+ dollar old Maseratis and other rare cars.

567chevys

09-06-2023, 07:46 AM

Brian ,

Was just looking at some of your Pictures and comments you are doing a great Job keep it up .

Thanks for sharing .

Sid

Custer55

09-12-2023, 01:21 PM

Amazing what you've done, Brian. You should be very proud.
Thanks, I feel like I am learning and getting better as I go.

Sweet! That is really looking great!
Thank You

It's a little late but my painter has been painting high-end cars for decades and he uses only one product to prep his cars. He uses a product called "All-U-Need" by Clausen. It's a zinc-enriched waterproof high build polyester primer. He sprays it thick on bare metal, blocks it, and sprays more and keeps blocking it until he gets the body straight. He probably uses some filler if needed but I think his metalwork is good enough that he doesn't need it much. He doesn't even worry about having bare metal spots. Then he shoots a coat of good epoxy sealer and paints the car. I wish I'd known about this stuff before I started prepping my Nomad for paint because it's a lot simpler and probably better and far less expensive process than what I did (PPG DPLF, Slicksand, PPG K-36). He says he's never had problems with it and he paints million+ dollar old Maseratis and other rare cars.
I will keep that in mind for the next project. Tamco also has a high build primer that is rust encapsulating and can be used directly over bare metal. You can prime the whole car with it if needed over the bare metal. I have been using the epoxy primer 1st because it seals the metal from rust as it can be a long time from when I get primer over the bare metal to when I get back to working on it again.

Brian ,

Was just looking at some of your Pictures and comments you are doing a great Job keep it up .

Thanks for sharing .

Sid
Thanks Sid

Custer55

09-12-2023, 02:01 PM

Finished up a couple of odds and ends the last week or so. I got the hood hinges and the trunk prop rod painted and re-installed. Just used spray cans to do these. Then repaired the trunk hinge bolts which were little carriage bolts that fit into the trunk weather strip gutter.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_120326-jpg.407352/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_120326-jpg.407352/
This is one of the bolts I am talking about. They were in good shape other than being partially rusted away on the bolt heads. Not surprising based on what the gutter itself looked like.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_121049-jpg.407353/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_121049-jpg.407353/
Here are the 4 bolts attached to some copper plate so I could weld the heads and then grind the head back close to the original shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_151240-jpg.407354/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_151240-jpg.407354/
After welding and grinding they look a little better. Not too worried about them being perfect as they will be hidden when weather stripping is added anyway.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_154611-jpg.407356/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230902_154611-jpg.407356/
Painted with some epoxy and bolted back in place now the trunk is ready to re-install. I always save any epoxy that is leftover from spraying parts in a small container. I have about 2 to 3 days before it gels up in the container so it comes in handy to do small parts like this with a small paint brush.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230903_115017-jpg.407357/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230903_115017-jpg.407357/
And with the trunk bolted back in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230910_130823-jpg.407358/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230910_130823-jpg.407358/
So next I started prepping one of the hood sides. Some rust damage that will need repairs but not too bad.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230910_130908-jpg.407359/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230910_130908-jpg.407359/
And a view from the inside. These are not fun to clean up with all the nooks and crannies in them. I like the look of the louvers but hate getting them ready for paint.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230910_130919-jpg.407360/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230910_130919-jpg.407360/
This is the worst of the rust on the hood side, which for sure will need a patch panel made. The lower edge has deeper pitting in a few areas but I will try to weld up the pits before resorting to patch panels in those areas. (mostly on the lower edge where the hood side meets the fender and inner fender. The rest of the panel is in pretty good shape.

Custer55

10-01-2023, 08:53 PM

Been busy with other projects the last couple of weeks but I did finally get back to working on the hood sides this past week.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_152448-jpg.409004/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_152448-jpg.409004/
Most of the lower edge where the hood side meets the fender and inner fender was in good shape other than some deeper rust pits. Rather than trying to make a whole new bottom edge I just welded up the rust pits as there were no rust holes so it was much faster to fix this way. From my experience you will know as soon as you pull the trigger on the mig welder if the metal is to thin to just weld up the pits as it will blow a hole right through the metal!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_152730-jpg.409006/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_152730-jpg.409006/
The lower rear corner had quite a few holes in it so I marked what will need to be replaced.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_154913-jpg.409008/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_154913-jpg.409008/Then made a paper pattern so I could better locate the indent in the lower corner I will need to replicate.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_163131-jpg.409009/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230925_163131-jpg.409009/Here is the metal cut out and the indent location marked. I left a bit of extra metal on the back and bottom edges.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230926_125847-jpg.409010/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230926_125847-jpg.409010/To make the indent I made a set of dies from 3/8" steel. My first test piece I figured out that 3/8" was thicker than it needed to be so I made a 3/16" spacer to get the depth better. Before pressing out the actual patch I also tuned up the small die a bit to make it a softer radius at the bottom of the indent. Also figured out on the first test piece that I needed to tack weld the sheet metal to the bid die so it wouldn't distort the whole piece when I pressed it out on the shop press.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230926_151933-jpg.409011/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230926_151933-jpg.409011/Here I have the patch panel fitted and clamped in place to to scribe the hood side where it will get trimmed out. Other than the indent and a small flange at the bottom this was a fairly easy piece to make as it is pretty much flat.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230926_155520-jpg.409012/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230926_155520-jpg.409012/All fitted up and ready to tack weld in place. I used magnets to hold it in place for the initial couple of tack welds. I picked these up at a local hardware store recently and they work great as they are super strong magnets.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230927_112505-jpg.409013/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230927_112505-jpg.409013/All tack welded in place ready to fully weld the seam. I have it tack welded about every half an inch and then ground all the weld flat on the inside and outside. I also did some hammer and dolly work as well as planishing the tack welds. Being such a flat panel there was some distortion to work out before the final welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230928_151927-jpg.409014/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230928_151927-jpg.409014/Welding the seam I used the same technique as I did welding the tail pan sections together. Starting at one end I did 3 tack welds at a time and then ground the welds on the outside of the panel smooth before doing the next 3 tack welds. By doing it this was it is not such a big job to do all the grinding at one time and it keeps me from rushing the process. Also I don't need to force cool anything this way either. The distortion wasn't bad either, other than right where the seam got pretty close to the louvers.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230928_151952-jpg.409019/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230928_151952-jpg.409019/And here is the back side of the panel after fully welding the seam. Weld penetration is great and the heat affected zone is fairly consistent which helps with smoothing everything out.
"to be continued"

Custer55

10-01-2023, 09:01 PM

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230928_162641-jpg.409020/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230928_162641-jpg.409020/With the inside weld seam ground smooth and most of the distortion worked out it is looking and feeling pretty good.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_105145-jpg.409021/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_105145-jpg.409021/Then I spayed some primer on the area to make it easier to tell where it needed a bit more work.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_120643-jpg.409022/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_120643-jpg.409022/After block sanding the primer, doing some more hammer and dolly work and some light work on the planishing hammer (my lowest crown die is a 6" radius so I didn't want to get to crazy with it) I think I am going to call this good to go.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_154335-jpg.409023/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_154335-jpg.409023/So on to the left hand hood side. This one needs a much smaller patch so should be a bit easier. I was able to use the big die for the indent by just flipping it over but I did have to make a new small die as the indent goes the other way from the right hand hood side.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_161835-jpg.409024/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230929_161835-jpg.409024/Fitted up and in place to tack weld in.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_143051-jpg.409025/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_143051-jpg.409025/Final welded and smoothed out. Not sure why but this one actually was harder to get smoothed out and get rid of a slight oil canning.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_143118-jpg.409026/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_143118-jpg.409026/So the next problem on this side was to fix the lower mounting holes. At some point these holes were cut out instead of adjusting things properly.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_153214-jpg.409027/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_153214-jpg.409027/After reforming the metal I welded in a small patch piece and them marked it where it needs to be cut back out.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_154839-jpg.409028/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_154839-jpg.409028/And the finished repair. Looking much better now.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_154846-jpg.409029/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_154846-jpg.409029/And here is the damage on the front hole. Repair procedure will be the same as the rear hole. Then I will have some rust pits to weld up but not as bad as on the other side. Once that is done it will be time to get epoxy primer on these. Being October 1st today my days are numbered for spraying epoxy as it needs to be a minimum of 60 to 65 degrees for proper curing. Most of the rest of this week looks ok but Friday the high is only supposed to be 52 degrees with lows in the 30's so we shall see.
Brian :cool:

BamaNomad

10-02-2023, 08:03 AM

Great work Brian! :)

chevynut

10-02-2023, 09:54 AM

Great job repairing that hood!

Custer55

10-02-2023, 11:13 AM

Great work Brian! :)
Thanks Gary

Great job repairing that hood!
Thanks Lazlo

TrifiveRichard

10-03-2023, 05:50 AM

The 39 is really taking shape, body is really looking good

Custer55

10-10-2023, 06:21 PM

The 39 is really taking shape, body is really looking good
Thanks Richard, Slow but sure it is getting there.

Custer55

10-10-2023, 07:06 PM

After finishing up on the hood side repairs I got them prepped and a couple of coats of epoxy sprayed on them before the weather cooled off.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_160618-jpg.409692/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_160618-jpg.409692/
Here is a shot of the last mount hole repair after reforming the area to weld in a patch.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_163323-jpg.409693/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20230930_163323-jpg.409693/
Here I have a patch piece welded in place. It just needs to be trimmed off and the hole opened back up, which I didn't get a picture of.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231003_130648-jpg.409694/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231003_130648-jpg.409694/
Here I have the pair of hood sides all ready for a couple of coats of epoxy primer.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231004_161024-jpg.409695/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231004_161024-jpg.409695/
Looking much better with primer applied on this one. Even with the cheapest Harbor Freight spray gun they sell the Tamco epoxy goes on pretty well.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_110831-jpg.409696/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_110831-jpg.409696/So with those done on to the front fenders and grill. Starting with the drivers side since it is in slightly better shape. Both front fenders will need some rust repair where they meet the running boards, but before I get to that I want to get the fenders as straight and dent free as possible. As you can see in this shot the shape of the fender doesn't match the grill very well in this area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_141621-jpg.409697/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_141621-jpg.409697/Before fixing the fender in that area I made repairs to the mount holes on the grill. I am assuming this damage was caused by the same thing that caused the fender damage.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_151826-jpg.409700/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_151826-jpg.409700/All the damage around the holes welded up using a copper backer (which I rarely use) then ground smooth and the holes opened back up in the proper locations.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_154601-jpg.409701/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231006_154601-jpg.409701/Here I have the fender fitting the grill much better. It took a bit of hammer and dolly work on the edge but mostly I got it back in shape by shrinking the flange. It was a challenge to hold the fender up and get the flange into the shrinker dies but it worked pretty well to reshape the fender.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231007_162941-jpg.409702/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231007_162941-jpg.409702/Then I started on smoothing out some dents in this area. I didn't get a before picture of the damage but it wasn't too bad. Also had to weld up a crack or two on the lower edge of the fender as well as a bad previous crack repair.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231007_162950-jpg.409705/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231007_162950-jpg.409705/And lastly from this angle you can see farther up in the wheel opening where I had to weld up some cracks at the edge of the wheel opening which will also need some hammer and dolly work to smooth it out better.
Brian :cool:

BamaNomad

10-11-2023, 08:11 AM

Brian, Great work as usual from you! :)

Have you had any issues priming over, or painting over the Tamco epoxy primer??

Custer55

10-12-2023, 07:18 AM

Brian, Great work as usual from you! :)

Have you had any issues priming over, or painting over the Tamco epoxy primer??
Thanks Gary!
I have not sprayed anything else over the Tamco yet. I don't think it will be an issue as long as I scuff it up good before spraying over it though.

Custer55

10-15-2023, 09:18 PM

Work continued on the drivers side front fender this week. After smoothing out a few more of the dents and welding up a couple of small cracks in a few spots I noticed some small rust pin holes on the flange where the fender meets the hood side and inner fender. There was a bit too many deep pits to just weld up so I made a small patch for this area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231012_125942-jpg.410009/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231012_125942-jpg.410009/Here I have the patch fit up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231012_153257-jpg.410010/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231012_153257-jpg.410010/And here it is all welded up and finished out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_122433-jpg.410011/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_122433-jpg.410011/The next problem to fix was the lower rear corner of the wheel opening. There is a tab for a fender brace at that corner which also had some stress cracks. I attempted to weld up the cracks but the metal was pretty thin in that area so it didn't turn out very well.
I made up these wood blocks to form a replacement piece.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_155434-jpg.410012/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_155434-jpg.410012/I first tried to make the new lower corner in 1 piece but it didn't work very well so I ended up making it in 2 halves. Here I have them tacked together.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_162621-jpg.410013/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_162621-jpg.410013/And here it is all welded up and finished out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_162652-jpg.410014/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231013_162652-jpg.410014/Here it is next to the corner it will replace. Should look much better and be much stronger than the original.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_105415-jpg.410015/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_105415-jpg.410015/Fitted up and ready to weld in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_105446-jpg.410016/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_105446-jpg.410016/And a view from the inside of the fender before welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_141630-jpg.410017/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_141630-jpg.410017/Welded up and finished out. I am pretty sure the passenger side fender will need same area repaired as well. I think I might try welding the outer half of the patch to the fender before welding the inner half of the patch in place. This should make it easier to finish out the welds on the outside of the fender. It was a pain on this one as the inner tab was in the way to hammer out the welds easily.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_141656-jpg.410018/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231014_141656-jpg.410018/And this will be the last of the repairs on this fender. I am going to attempt to make the patch for this in one piece but not too sure how well that will go. There is a good possibility that it will need to be done in multiple sections, as the shape has to fit to the running board pretty close. We will see what happens.
Brian :cool:

Belair-o

10-18-2023, 08:16 AM

Hi Brian,
Really liked the tip about the wooden forming blocks. I will have to stuff that one in my brain, not that I will likely know where to access it there!
Thanks! Doug

WagonCrazy

10-20-2023, 06:12 AM

Great progress! and great updates here. Thanks for sharing your techniques. it helps all of us.

Custer55

10-22-2023, 06:33 PM

Hi Brian,
Really liked the tip about the wooden forming blocks. I will have to stuff that one in my brain, not that I will likely know where to access it there!
Thanks! Doug

Thanks, There are a lot of ways to from metal, making the wood blocks seemed like the best way in this case as I will most likely need to make one for the passenger side front fender as well.

Great progress! and great updates here. Thanks for sharing your techniques. it helps all of us.

Thanks, I hope it does help others on their projects. I have been learning as well by watching videos on you tube. My favorites to watch are Karl Fischer (Make it Kustom) and Carter Auto Restyling, They are both out of Western Canada.

Custer55

10-22-2023, 07:35 PM

The past week I finished up on all the fender repairs and have it ready for epoxy primer.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_104541-jpg.410423/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_104541-jpg.410423/This was my attempt at making the patch in one piece. It became obvious pretty quickly that while I was making progress it was taking way to much time to get it to where it would fit properly.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_110036-jpg.410424/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_110036-jpg.410424/So time for plan B which will require more weld seam but will end up fitting much better and take less time in the end. The first thing I did was bend a half inch flange and then use my shrinker to shape the piece to fit the shape of the fender and where it will meet the running board.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_161613-jpg.410425/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_161613-jpg.410425/Then I made a second piece to fit the lower part of the fender. This was still a challenge to make as it has a reverse curve to it similar to a 55 Chevy fender below the parking lights.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_200013-jpg.410426/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231016_200013-jpg.410426/Then before welding either of those in place I replaced the rotted out section of the inner bracing where the fender meets the running board. Just tacked in place here but I did fully weld it up before proceeding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_115542-jpg.410428/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_115542-jpg.410428/Here is the 1st piece fitted, tack welded, and plug welded in place. I did check the fit to the running board while it was just tack welded before doing the plug welds.
Also I only cut away as much of the rusted area of the fender as needed at this point so I could tweak the 2nd patch section to fit while the original shape of the fender was still there.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_144523-jpg.410429/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_144523-jpg.410429/Here the upper part of the patch is fit up pretty close ready to start welding it in place.
I didn't cut out any more of the original fender than I had to to make fitting the patch a bit easier.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_155640-jpg.410430/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_155640-jpg.410430/All tack welded in place. Just need to grind all the tack welds flush before fully welding up the seams.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_204152-jpg.410431/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231017_204152-jpg.410431/And fully welded and finished out. Far from perfect but way better than having all the rust holes. I was able to get the fit a little better with some hammer and dolly work at this point as well. It will just need a thin coat of body filler at this point.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231018_104636-jpg.410432/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231018_104636-jpg.410432/And the last repair on this fender was to fix a couple of spots where the bolt holes were really close to the edge and good candidates for future cracks. I just added a bit of metal right at the holes. One finished repair and one in progress in this shot.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231019_114231-jpg.410433/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231019_114231-jpg.410433/After some time with a wire wheel and 80 grit I got the inside and outside of the fender ready for primer. I was going to attempt putting it on with a brush but after trying that on a few smaller part I wasn't happy with the results. Our weather has been in the mid 50's for highs with lows in the mid 30's recently and should stay that way through most of next week so I decided to turn on the heat in the shop to get a few more things in primer.
I don't like to have the heat on with an open flame (gas heater) as I need to have the garage door open at least a crack when spraying the epoxy primer. It has been staying close to 60 in the shop though so I won't need to run it much to get it up to the 65 I need it to be for the epoxy to cure properly. The passenger fender will most likely have to wait until spring for primer though as the 10 day forecast for the following week shows high temps only in the mid 30's. Winter is on the way!!
Brian :cool:

Custer55

10-26-2023, 06:35 PM

This week I was able to get a few more things in epoxy primer as the weather has been cooperating for the most part.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231022_123839-jpg.410780/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231022_123839-jpg.410780/Drivers side front fender all done. I had a little primer left over so I ended up getting a couple grill parts which had already been sand blasted that didn't need much prep work in primer as well. By hanging the fender up I was able to paint the inside and outside at the same time, although the outside wasn't in the ideal position.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231022_123852-jpg.410781/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231022_123852-jpg.410781/View from the inside of the fender with one of the grill parts in the foreground. The grill on this car is made of 5 pieces that all bolt together, which made it possible to sand blast in my cabinet with it all apart.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231025_152510-jpg.410782/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231025_152510-jpg.410782/Here is a better shot of the fender after it was cured enough to take it down. Looks much better than what I started with.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_140713-jpg.410783/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_140713-jpg.410783/Next up was the outer grill halves. The drivers side had a few rust pin holes on the lower end which were too much to just weld up so I ended up making a small patch in this area. The passenger side was in better shape and just needed a couple of small cracks around some bolt holes welded up after getting it sand blasted.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_140450-jpg.410784/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_140450-jpg.410784/Here I have the patch formed up and clamped in place to scribe the grill for the area to cut out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_145536-jpg.410785/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_145536-jpg.410785/All fitted up and ready to tack weld in place. Compared to the patch for the fender I just did this one was a lot easier to make.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_154559-jpg.410786/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_154559-jpg.410786/All tacked in place and ready for final welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_185845-jpg.410787/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231023_185845-jpg.410787/All welded up and finished out. I am pretty happy with how this one turned out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231026_122430-jpg.410788/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231026_122430-jpg.410788/All five pieces of the grill now in primer and ready to re-assemble once the paint cures better.
With the shop between 60 and 65 degrees the epoxy primer takes a while longer to cure so I will give it a week or two.
So the next project will be the passenger side fender which will just about wrap up all the metal work on the body. The last thing will be the running boards and then the dash and the windshield inside trim in the lower right hand corner. No hurry on any of this though as the high is only supposed to be 40 degrees on Saturday and the foreseeable future so all of those will be a while before they can get epoxy primer anyway.
And my shop needs a good cleaning and I have a bunch of projects in the shop and around the house to get done that I have been putting off as well.
Hopefully I will be back on the passenger fender soon though.
Brian :cool:

chevynut

10-26-2023, 08:19 PM

That's looking GREAT Brian! You've come a long way. To tell the truth I'm kinda missing the metalwork.

Custer55

10-26-2023, 08:24 PM

That's looking GREAT Brian! You've come a long way. To tell the truth I'm kinda missing the metalwork.

Thanks Lazlo!
I enjoy the challenges of metal working, very satisfying when stuff turns out halfway decent.

bigblock

10-27-2023, 05:18 AM

Looking great I love the detail that you show us, I hope mine will be half as good as yours. :)

busterwivell

10-27-2023, 05:39 AM

Like the others have said, you do amazing work, Brian. You should be very proud. It's been fun watching your progress.
Bill

Custer55

10-27-2023, 09:20 AM

Looking great I love the detail that you show us, I hope mine will be half as good as yours. :)

Like the others have said, you do amazing work, Brian. You should be very proud. It's been fun watching your progress.
Bill

Thanks guys! Glad you are following the progress. This has been a good car to learn on. Still worth saving but not so nice to worry about messing it up.

Custer55

01-04-2024, 07:29 PM

It's been a couple of months since my last update. After getting epoxy primer on the grille pieces I have been working on a bunch of other projects. First off was getting all the leaves cleaned up as they fell from the trees around the yard. We have woods around most of the yard so that takes a while!! Then spent a couple of weeks cutting and splitting firewood for the winter season. Haven't used any of it yet though as December and early January have been way warmer than normal so far. After changing oil in my 55 and 95 Trans AM I ended up building a taller and wider set of car ramps than what I had. The old ones I have been using for years were only 6 inches high and wide so I finally decided it was time for some better ones. I have not used them yet but should make that job much easier.
Next up was cleaning up the corner of the shop where I stash all the metal scraps that are still big enough to save. That had become a big mess as I save too much of it. I ended up filling a bunch of 5 gallon buckets with metal to go the recycling yard.
Then I built stands for my sheet metal shear and bending brake instead of having to bolt them to my welding table when I needed to use them.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134423-jpg.416349/Here are the two stands. I built both of them mostly with material from the scrap metal pile. Both have wheels to make them easy to move around. On the bending brake I added a brace to the clamp bar and tack welded c-clamps to the clamp bar and underneath on the base so that should make it easier to use as well. In the background to the right are all the 5 gallon buckets filled up with scrap metal.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134616-jpg.416350/https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134616-jpg.416350/
So finally last week I got back to working on the passenger side fender. A little less rust than the drivers side where it meets the running board, so that should be a little easier to repair. The lower corner of the wheel opening will need a similar repair to the drivers side as well. The rest of the back half is not to bad, just a few smaller dents to smooth out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134833-jpg.416351/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134833-jpg.416351/The outer front corner is another story. This area was damaged at some point and the previous attempt at repairs were not done very well. Luckily the damage is only on the outer part of the fender. The headlight area and where the grille bolts in place are in good shape yet.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134914-jpg.416352/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134914-jpg.416352/In this shot from the inside of the fender shows how poorly the repair was done. They must have just ground off the high spots creating holes in the metal. So once I get the fender smoothed out and back close to the right shape a patch will have to made to replace this area. Way to many holes and way to much thin metal to even consider welding up the holes.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_135606-jpg.416353/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_135606-jpg.416353/Then there is these areas they tried to weld up cracks in the fender lip on the lower front corner. Not sure what kind of welder they used but it didn't work very well.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_135616-jpg.416354/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_135616-jpg.416354/And this mess in the middle of the wheel opening.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231231_161027-jpg.416355/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231231_161027-jpg.416355/I tried grinding out the old welds on the fender lip to see if I could save any of it but decided to just cut them out and just plan on making new pieces to weld in place to repair the fender lip.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134554-jpg.416356/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231229_134554-jpg.416356/The good news on this fender is that the inside edge is in good shape. Just a few minor spots to weld up and the front fits the shape of the grille pretty good.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231231_160943-jpg.416357/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231231_160943-jpg.416357/So before making and welding in any patches I want to get all the damage smoothed out and the correct fender shape as good as I can get it. The back half still need some work but it's close enough to move on at this point.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231231_160953-jpg.416358/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20231231_160953-jpg.416358/On to the front half. This will be a challenge as it is pretty rough and will most likely need some heat shrinking as well. Nothing to lose here though as it would be hard to make it any worse. I think the general shape is close so mostly I just need to smooth out the damage, shrink any metal that needs it and then start with the repairs to the wheel opening.
Should be a fun project!!
Brian :cool:

bigblock

01-05-2024, 06:01 AM

Thanks on all your updates :)

Custer55

01-08-2024, 04:52 PM

Thanks on all your updates :)
Your Welcome, Glad to have time to work on the 39 again!
Brian

WagonCrazy

01-09-2024, 10:44 AM

Great updates. Stay at it. Gonna be a beautiful old car when done.

Custer55

01-11-2024, 05:42 PM

Great updates. Stay at it. Gonna be a beautiful old car when done.
Thanks, I will keep the updates coming!

Custer55

01-11-2024, 06:42 PM

Continuing on the passenger side front fender repairs. After a lot of time with hammer and dollies, a bullseye pick (which I made myself, will post a picture one of these days), torch shrinking, planishing, and finally my shrinking disc I got the damage smoothed out enough to go ahead and start on the metal repairs.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240105_124536-jpg.416951/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240105_124536-jpg.416951/Far from perfect but much better than it was. The first repairs will be to the wheel opening lip to stabilize everything.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240105_124700-jpg.416952/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240105_124700-jpg.416952/And a view from the front where most of the damage was. I will still need to make a patch panel where the metal was ground too thin and created holes.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240106_144311-jpg.416953/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240106_144311-jpg.416953/First patch formed up and fit up to tack weld in place. The cut out area above this patch had a couple of cracks so I will make a small patch for that as well.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240107_104530-jpg.416954/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240107_104530-jpg.416954/Tack welded in place so I can make and fit up the upper section of the patch. Looks like it would just be a flat piece but it did have a slight crown in both directions so my planishing hammer worked well to make that piece.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240107_130230-jpg.416955/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240107_130230-jpg.416955/Upper section formed, fitted, and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240108_151128-jpg.416956/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240108_151128-jpg.416956/Fully welded and finished out. At this point I had left the lower part of the patch at a 90 degree angle vs forming it completely before welding it in figuring it would be easier to planish out the welds that way. Then I formed it over to match the profile of the of the inside edge of the fender lip and finished welding it in place. I don't think I would do it that way again though as when I formed it over it threw off the shape on the outside. So I had to do quite a bit of hammer and dolly work on the inside of the lip to stretch it out enough to get the shape back where it belonged.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240109_145148-jpg.416958/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240109_145148-jpg.416958/Here it is all finished up. Looks good but I would form the inside to shape before welding the patch in place next time. I would still have to hammer and dolly it to get the correct shape but it would be much easier to do that before it was welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240109_155154-jpg.416959/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240109_155154-jpg.416959/Here is the next section to repair at the bottom front corner of the wheel opening. Just as I did on the first wheel opening piece I started with a straight piece and bent it on my bending brake. I needed a 5/16" radius bend to match the fender so I make 6 bends of about 15 degrees each, 1/16" apart. The recent modifications I made to my brake made this job much easier.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240109_161815-jpg.416961/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240109_161815-jpg.416961/I used my shrinker and planishing hammer to form the shape needed to fit the fender.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240111_143737-jpg.416964/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240111_143737-jpg.416964/And finally fitted up ready to tack weld in place. I formed the inner edge to the correct shape on this one so that should make this one easier to finish out.
Wasn't sure how well this fender would turn out but so far it seems to be going ok.
Brian :cool:

Custer55

01-23-2024, 05:26 PM

Work continuing on the passenger side front fender last week.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_152903-jpg.417786/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_152903-jpg.417786/This patch fitted up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_115856-jpg.417789/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_115856-jpg.417789/Next was to form up a patch for the very bottom front corner. I made this one a bit higher up into the fender as there was a crack in the fender in this area so the larger patch took care of that at the same time as the bottom edge.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_142930-jpg.417790/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_142930-jpg.417790/Getting close to being ready to tack weld in place at this point.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_152935-jpg.417791/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_152935-jpg.417791/All fitted up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_153002-jpg.417792/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240115_153002-jpg.417792/And a view from the bottom of the lower flange of the fender. It looks much better than the mess I started with now. The thin spots/holes from the previous old repairs are clearly visible in this photo as well.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240116_141922-jpg.417793/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240116_141922-jpg.417793/Next up was the lower rear corner where the fender brace bolts to the fender. Same repair as I had done on the drivers side fender but I decided to do this one differently.
On the drivers fender I made the patch out of 2 pieces and welded them together before welding it into the fender. On this one I welded the outer half into the fender before welding the inner half of the patch in place. This made it easier to finish out the welds on the outer half of the patch shown tack welded in place here.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240116_152328-jpg.417796/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240116_152328-jpg.417796/Here it is fully welded in place and finished out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240116_152413-jpg.417797/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240116_152413-jpg.417797/And here is the inside view of the patch ready to weld the inner half to the patch in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240117_120735-jpg.417798/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240117_120735-jpg.417798/And here I have the inner half welded in place and finished out.
Next up will be fixing the rust where the fender meets the running board as I did on the drivers side fender.
Brian :cool:

Custer55

01-28-2024, 07:55 PM

The next step on the passenger side front fender was to repair the area at the bottom rear where it meets the running board.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240118_153700-jpg.418145/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240118_153700-jpg.418145/Here I have the inner structure repaired. As you can see the rust holes are confined to the very corner so I was able to make the patch for this in one piece instead of the two pieces I did on the drivers side fender.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240119_153748-jpg.418146/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240119_153748-jpg.418146/Here I have the patch all formed up and ready to fit up for welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240124_105024-jpg.418147/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240124_105024-jpg.418147/All fitted up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240125_120156-jpg.418148/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240125_120156-jpg.418148/View from the inside with the seam fully welded.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240125_125609-jpg.418149/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240125_125609-jpg.418149/And the inside view after grinding out all the welds and planishing out the weld seam.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240125_125807-jpg.418150/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240125_125807-jpg.418150/And the view from the outside. This one turned out pretty well, not perfect but it won't need much filler. I just need to drill out the mount holes to finish this repair.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240126_142823-jpg.418152/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240126_142823-jpg.418152/At this point I finished welding up the seams on the two patches on the bottom front corner so I am ready to tackle making a patch panel for the area with the holes from the past poor repair.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240126_144557-jpg.418154/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240126_144557-jpg.418154/The first step in that process was to make a paper pattern of the area the patch will need to cover. I had a light behind the fender when I took this picture so you can see holes where the light is shining through the paper. Where the paper pattern has the wrinkles indicates where the metal will need shrinking to create the needed shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240127_111130-jpg.418156/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240127_111130-jpg.418156/Starting to take shape after doing tuck shrinks around the outside edge. I also did a bit of stretching in the middle of the patch on the planishing hammer at this point.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240127_163608-jpg.418157/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240127_163608-jpg.418157/It has a ways to go yet here but getting closer after smoothing it out on the planishing hammer and a a bit more shrinking on the edges.
So that is where I left off yesterday. Hopefully by my next update this fender will be done!
Brian :cool:

bigblock

01-29-2024, 05:49 AM

Awesome work!!

Custer55

02-02-2024, 11:12 AM

Awesome work!!

Thank You! :cool:

chevynut

02-04-2024, 09:20 AM

Custer55

02-04-2024, 06:58 PM

Wow, you're really getting good at this!!! Lots of practice. Curious what welder settings you're using to get that great penetration. What size wire? I have a Miller 211 with Autoset and I have to run it at the high end of the metal thickness setting to get good welds.

You mentioned the warm winter. We've hardly gotten any snow in Colorado and it's been in the 50's and 60's here. The weird thing is that it's been warmer a lot of days in Montana than in Colorado, but only by a degree or two. A week ago it was 49 degrees at our place at 10PM at night. We got about 16-18" of snow a a couple weeks ago and it's pretty much all melted but we got an inch or two last night. February and March is the heavy snow season in both places.

Thanks, lots of practice helps for sure!
I use .030 wire for everything so I don't have to switch back and forth since I just have the 1 welder. (Lincoln 125, 110 volt) I set my heat a couple of settings above what it states with the info that came with the welder, and the wire speed just a bit higher. My welder has the infinite adjustment knobs so I can fine tune the settings as needed.
Also vary how long I am on and off the the trigger. It's always a moving target as my patches are 18 gauge (.045 to .048) vs the original metal be 19 gauge which can be from .040 to .030 due to thinning from the stamping process and 80 plus years of rusting. I try to get things fitted up with the gaps as tight as possible but they are never perfect either. Once the patches are tacked in place, ground flat and planished out I fully weld the seams by starting at one end and working my way to the other. I do 3 or so tacks at a time with a short pause between each tack. I start each tack just a bit away from the previous tack and move the weld puddle into the previous tack. I don't cool the welds with air of water. After each set of tacks I grind the tacks I just did about 80 to 90% flat on the outside only and then let it cool until I can put my bare hand on it before doing another set of tacks. Once the hole seam is fully done then I grind it all flat outside and inside If I have good access, then planish the weld seam and bodywork the whole area good enough that it will just need a thin coat of filler. It has been working well for me using this method but it is a fine line between getting full penetration and blowing holes. You will know right away when you cross the line which does happen sometimes!!

Custer55

02-04-2024, 08:08 PM

Work continued on the passenger fender this past week.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240128_122746-jpg.418810/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240128_122746-jpg.418810/After getting the fit pretty close I welded tabs to the patch panel so I could screw it in place to make the final fitment and tack welding in place easier.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240128_153442-jpg.418811/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240128_153442-jpg.418811/After a bit more tweaking the shape I have it fitted up and ready to tack weld in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_105438-jpg.418812/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_105438-jpg.418812/All tacked welded in place but I had a bit of a setback here. While planishing out the tack welds to prep for fully welding the seam I found an area (circled in blue) where I should have made the patch panel bigger. The original metal was a lot thinner than I thought in this area so a 2 piece patch panel it is.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_105554-jpg.418813/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_105554-jpg.418813/So I formed up another patch to go up high enough to get rid of the super thin metal.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_114133-jpg.418814/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_114133-jpg.418814/Here I have most of the area for the new patch cut out. By cutting out just the middle it makes it easier to form the patch as you can hold it up from the backside as well as the front side to check the fit.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_142012-jpg.418815/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_142012-jpg.418815/Here it is fit up and ready to tack weld in place. Just using magnets on the back side to hold this one in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_162217-jpg.418816/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240130_162217-jpg.418816/Tack welded in place ready for final welding.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240131_113916-jpg.418817/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240131_113916-jpg.418817/On this one I fully welded and finished out the seam between the 2 patch panels before doing the rest of the seam so it is basically one bigger patch panel at this point.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240202_122519-jpg.418818/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240202_122519-jpg.418818/And finally all welded up and finished out. Finishing it out was a process of planishing the weld seams, hammer and dolly & bulls eye pick on the low spots, knocking down a few high spots and then using a vixen file and shrinking disk to smooth it all out better. So this fender is ready for prep and epoxy primer once we get some weather in the 60 degree plus range. That will be a few months yet around here.
Overall I am pretty happy with how it turned out. At least it is way better than what I started with!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240202_123004-jpg.418819/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240202_123004-jpg.418819/As promised here is a shot of the bullseye pick that I made. Don't look at the crappy bends on the tubing as it was some scrap that I had on hand but is very thin wall and kinked more than it bent. I did make the pick end removeable so I can make different tips if I need to. Also I need to add a return spring eventually, or just build a whole new one with a bit heavier tubing. I does work pretty well though as it makes getting those pesky little low spots a lot easier to smooth out, as you can hit the exact spot you need to knock them up a bit.
So my next project will be fixing a rusted corner on the dashboard and getting that ready for primer.
Brian :cool:

Custer55

02-14-2024, 06:23 PM

So my next project was fixing a rusted corner on the dashboard caused by a leaking windshield would be my guess.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240202_152417-jpg.419659/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240202_152417-jpg.419659/Here is what the dashboard looked like before working on it. About what you would expect for a car that is about 85 years old. The good thing is that it is pretty easy to remove it from the car, just a few sheet metal screws at the top and a couple of 1/4" bolts at the bottom.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240203_105215-jpg.419660/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240203_105215-jpg.419660/The rust damage is all in this corner from the leaking windshield on the passenger side. These cars had crank out windshields which are pretty cool but probably not such a good idea for keeping water out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240204_104147-jpg.419661/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240204_104147-jpg.419661/To simplify things I made the patch in 2 pieces. Here is the first one formed up which was just bending to match the radius at the top and the flange where the dashboard screws to the body.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240204_112831-jpg.419662/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240204_112831-jpg.419662/All fitted up and tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240205_141450-jpg.419663/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240205_141450-jpg.419663/Here I have the corner piece formed up pretty close. This one was harder to make as this was my 3rd attempt at it. I had originally intended to make the patch down to where the sharpie line is to get rid of all the little rust pits on the back side. I ended up making it smaller to get it to fit better figuring if I needed I could just weld up a few rust pits if needed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240205_145240-jpg.419664/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240205_145240-jpg.419664/Here I have it all fit up ready to tack weld in place. Putting the weld seam on the inside corner of the body line made the patch easier to make but it was a bit more work to grind out the weld seam that way.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240205_161437-jpg.419665/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240205_161437-jpg.419665/All tack welded in place and the outside edge trimmed and tipped over to match the original dash shape in the upper corner.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240206_162536-jpg.419666/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240206_162536-jpg.419666/All welded up and finished out as well as adding the slotted mount holes and notch for the inside trim screw added.
https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240208_110636-jpg.419667/

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240208_110636-jpg.419667/Here is and overall view after getting rid of all the old paint and light surface rust so It won't be so much work to prep for primer once the weather warms up in a few months.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240209_140413-jpg.419668/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240209_140413-jpg.419668/And finally somewhat re-assembled and installed back in the car to check the fit. I had to tweak the corner a bit where I did the patch panel but it looks good compared to what it was. Now I need to repair the inside windshield trim for the passenger side but I may work on some other things before I tackle that. I have to think about the best way to do it as the corner is completely gone in the same are where the dash needed the repair. I might search ebay for a replacement part but I am not optimistic about finding one at a reasonable price.
I have not had any luck finding one at a swap meet over the past years either, so we will see what I can come up with to repair it if I can't find a replacement.
Brian :cool:

TrifiveRichard

02-14-2024, 06:34 PM

Looks nice, you're really getting proficient at metal working, Brian. Thanks for sharing!

bigblock

02-15-2024, 05:36 AM

Man Brain that's some more beautiful craftsmen's ship.

WagonCrazy

02-15-2024, 06:54 AM

Fantastic work and thank you for documenting it here.
BTW. what gauge of sheetmetal are you using for most of these patch panels?

Custer55

02-15-2024, 04:42 PM

Looks nice, you're really getting proficient at metal working, Brian. Thanks for sharing!
Thanks, I agree that I have been getting better at metal working since I started this project!

Man Brain that's some more beautiful craftsmen's ship.
Thanks

Fantastic work and thank you for documenting it here.
BTW. what gauge of sheetmetal are you using for most of these patch panels?
I have been using 18 gauge which is thicker than the original metal, but that way I can file and sand on it to make it smoother without worrying about making it too thin.

Custer55

02-27-2024, 07:19 PM

After looking at the inside windshield trim I decided to work on some other things before taking that on. So I dug out the old windshield frame and and what was left of the glass to work on that.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240209_152517-jpg.420921/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240209_152517-jpg.420921/Here is what is left of the windshield. The glass is in terrible shape and will need to be replaced. Even if it was in decent shape it would be a good idea to replace it as it is not safety glass and turns into glass shards when it breaks.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240209_152557-jpg.420925/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240209_152557-jpg.420925/The frame is made in 2 pieces (held together in the middle where the 4 screws are) with a seal around the outside where it fits into the body. So after breaking out what was left of the glass and disposing of that mess, I got the screws removed (or broken off) and the frame apart with lots of heat and penetrating oil.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240212_143028-jpg.420926/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240212_143028-jpg.420926/After getting all the old outside seal removed I made a tray lined with 4 mil plastic doubled up to soak the frame in milkstone rinse and water to remove the rust since it would not fit in my sandblast cabinet. It took about 3 days but did a good job of getting rid of the rust without hurting the chrome that was still in decent shape.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240216_102649-jpg.420927/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240216_102649-jpg.420927/Here is a view of the inside of the frame after rust removal.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240216_102540-jpg.420928/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240216_102540-jpg.420928/Here is the outside view. I ended up grinding all the chrome off of the outside as it was in very bad shape. Not worth having this one re-chromed either due to it's condition so the plan is to just paint it at this point. The lower left corner needs the chrome ground off yet so you can see what the condition was.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240216_160249-jpg.420929/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240216_160249-jpg.420929/Here is it with all the chrome ground off and re-assembled. I will probably use a paint that gives it a brushed aluminum look similar to how it looks now, which should look better than rusty chrome.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240217_155522-jpg.420930/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240217_155522-jpg.420930/And back in the car and adjusted to the opening or at least close enough for now until I get glass and the outer seal back on it.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240217_155610-jpg.420931/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240217_155610-jpg.420931/And here it is in the fully open position. Easy to see why this had so much rust damage as I can't see how these would not leak after being open and closed a few times. Would probably be better to just seal it closed to keep it from leaking.

(Continued below)

Custer55

02-27-2024, 07:24 PM

With the windshield back in place I have been working on some odds and ends. Since I had the tray with the rust remover set up I dug out a bunch of parts to soak to remove the rust.
Not all of them were to big for the blast cabinet, but that way I could work on other things while the parts were soaking. I cleaned up and oiled all the window regulators and put them all back in the car.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240221_111852-jpg.420932/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240221_111852-jpg.420932/One of the parts I de-rusted was the inside rear window trim. For the most part this was in good shape other than some deep rust pits on one of the lower corners. I made up a piece of copper to weld up the pits without making a bigger mess as these are made out of thinner metal than the body in the 1st place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240221_120309-jpg.420933/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240221_120309-jpg.420933/All the pits welded up ready for some grinding and filing.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240222_110858-jpg.420934/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240222_110858-jpg.420934/All ground and filed out. Using a flat hand file to do the final finishing works well.
100% good enough anyway as nobody will see this edge once the trim is installed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240222_110916-jpg.420935/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240222_110916-jpg.420935/And a shot of the outside that will show inside the car when installed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240226_102140-jpg.420936/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240226_102140-jpg.420936/Here is a few part I got some spray bomb paint on late last week on one of our nice days between the cold days. (Rustolleum primer and Satin black)

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240227_140704-jpg.420937/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240227_140704-jpg.420937/Today I got paint on these parts which are mostly the bumper brackets. Almost 70 degrees for a high today and the high tomorrow is only supposed to be 23 degrees, and then back up to the 60's this weekend. Very unusual weather this winter for sure!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240222_122908-jpg.420938/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240222_122908-jpg.420938/So this will be my next project. These are the lower windlace retainers that go below the dashboard at the front of the door. Will need some small patches for rust on one end but should be fairly easy to do. At least with the up and down weather I am able to get things ready to paint between the nice days so that has been a plus!
Brian :cool:

Belair-o

02-28-2024, 08:23 AM

I appreciate your patience and persistence. I fear I would have taken a BFH to some of the parts you are restoring and then rued the day I did so. Nice work!

Custer55

03-10-2024, 05:17 PM

I appreciate your patience and persistence. I fear I would have taken a BFH to some of the parts you are restoring and then rued the day I did so. Nice work!

Thanks, I have days like that too. That's why I don't keep the really big hammers in the work shop.

Custer55

03-10-2024, 06:34 PM

I have been continuing to prep and paint parts as the weather cooperates. Got a bunch of small parts done before the weather got cooler again so I went back to doing some repairs on various parts.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240229_105148-jpg.422287/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240229_105148-jpg.422287/Welded in patches on these from the last post (I called them windlace retainers but I think they are actually called kick panel retainers) so they are now ready to paint.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240229_105258-jpg.422288/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240229_105258-jpg.422288/This is the rusted out end of a rear fender brace. This will get cut off and repaired.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240229_120021-jpg.422289/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240229_120021-jpg.422289/Here I have a new end welded in place. Once I get the end bent into the original shape it too will be ready for paint.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_103925-jpg.422290/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_103925-jpg.422290/Next I decided to try and repair the inside windshield trim. The painted one on the left is for the drivers side. What's left of the passenger side piece is on the right. Same rust issue as the dashboard from the leaky windshield.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_104013-jpg.422292/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_104013-jpg.422292/In this picture I have a trim piece I got at Jefferson swap meet last spring from a 40 Ford. It is similar to my 39 Ford Standard but not a direct replacement for sure. I am hoping I can use just the lower corner to repair my original.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_120236-jpg.422293/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_120236-jpg.422293/On the left is a piece of my Original trim and on the left is the 40 Ford trim. Quite a bit different profile so it will take some trimming and re-shaping to make it work.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_121345-jpg.422294/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_121345-jpg.422294/So I cut the rusty ends off of the original trim and screwed them in place in the car so I would know how much of the 40 Ford trim piece will be needed.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_121409-jpg.422295/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_121409-jpg.422295/I then cut that area out of the 40 Ford trim piece and set it in place. Looks like it could work if I can get the shape to match the original 39 Ford trim piece.
Brian

"To be continued below"

Custer55

03-10-2024, 06:43 PM

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_135058-jpg.422297/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240305_135058-jpg.422297/To re-shape the 40 Ford trim I made patterns of the outside and inside shape of the original trim to make some profile dies.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240308_120155-jpg.422298/https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240308_120155-jpg.422298/
Here I have the profile dies made from 3/8" thick stock bolted into a modified vise grip. I modified the vise grip to bolt the profile dies into it vs welding them in so I can use it on other projects by making different profile dies to bolt in.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240308_120359-jpg.422299/https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240308_120359-jpg.422299/
I found it was easier to use the tool by clamping it into a bench vise as shown here. Not a perfect solution but it got the trim piece close enough to make it work. When I get some time I may try to set up my planishing hammer to be able to bolt the profile dies into that to see if it works better. Pretty sure that would be easier than the vise grip method for smaller parts.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240308_123546-jpg.422300/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240308_123546-jpg.422300/It took a while but I got the 40 Ford Trim piece pretty close to the same profile as the 39 Ford Trim piece. (original on the left, 40 Ford on the right)

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240309_142119-jpg.422301/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240309_142119-jpg.422301/Then I got the modified 40 Ford trim piece fit up in the corner and added the screw holes and screw hole dimples with a tool I made. Just a piece of 1/2 x 1/2 steel drilled and tapped with a counter bore at the top so I could form the dimple with a flush mount flat screw similar to the original trim screws.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240310_100344-jpg.422302/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240310_100344-jpg.422302/Here the original upper part of the trim installed and the new corner fitted up ready to tack weld together. I tack welded them together in place on the car and then removed them as a unit to finish welding them together.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240310_115900-jpg.422303/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240310_115900-jpg.422303/After welding and finishing out that seam I fitted up the last piece to tack weld in place.
At this point I have the windshield frame in the fully open position as that is the only way these trim piece and be installed and removed when they are one piece as original.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240310_141510-jpg.422304/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240310_141510-jpg.422304/And here it is all welded up ready for prep and paint next to the drivers side trim on the left.
Not exactly the same as the original piece but close enough for me and way better than having a completely missing lower corner.
Brian :cool:

Belair-o

03-11-2024, 08:05 AM

Hi Brian,
Your profile die pliers idea is great! Thanks for sharing your innovative ideas that don't require a bunch of tools to implement!
Thanks! Doug

Custer55

03-11-2024, 11:50 AM

Hi Brian,
Your profile die pliers idea is great! Thanks for sharing your innovative ideas that don't require a bunch of tools to implement!
Thanks! Doug

Thanks Doug, I have been watching metal shaping videos on you tube which gives me lots of ideas.

Custer55

03-19-2024, 05:45 PM

Continuing to work on odds and ends parts I got a few more things painted last week while the weather was still cooperating. Looks like that will be on hold for a while though as the 10 day forecast is for at or below average temps which means highs of about 40 or less.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240312_153750-jpg.423137/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240312_153750-jpg.423137/These are the headlight buckets for the 39. I soaked these in the Milkstone rinse (phosphoric acid) for about 4 days then just a light sandblasting cleaned them up nicely.
I decided to just cut off the sockets where the wiring goes into them and will just use a rubber grommet instead.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240314_122953-jpg.423138/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240314_122953-jpg.423138/One good thing is these are the same for left or the right fender so no worries about mixing anything up. They are in decent shape other than a few rust pin holes that needed to be welded shut on the right one. The one on the left will need a small patch at the bottom.
The brackets inside which hold the reflectors and and bulbs are in good shape and function as they should. I don't have the reflectors however as someone had replaced them at some point with 6 volt sealed beam lamps and discarded the reflectors.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240314_142238-jpg.423139/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240314_142238-jpg.423139/Here I have the lower lens tabs and the tab for the headlight lens bezel removed and the bad section of the bucket that will need to be replaced. The 3 little tabs at the bottom were riveted in place and the inner part of the bucket is solid so relocating the tabs will be easy by using the same rivet holes.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_112633-jpg.423140/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_112633-jpg.423140/Replacement patch all formed up and fitted ready to weld in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_143733-jpg.423141/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_143733-jpg.423141/All welded in place (bucket on the right) and the bezel tab riveted back in place. I just used 1/8" pop rivets from the back side and then peened them over on the lens and bezel side.
Bucket on the left shows how the little tabs are needed to hold the headlight lens in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_162342-jpg.423142/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_162342-jpg.423142/The lower lens tabs were in pretty bad shape so I made new ones and pop riveted them in place. You can actually buy the replacement tabs but they weren't that hard to make.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_162357-jpg.423143/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240315_162357-jpg.423143/And here is a close up view. I had to tweak them a bit to get the lens to fit correctly but good enough as they will not be visible with the lens and bezel in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240318_123250-jpg.423144/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240318_123250-jpg.423144/This will be my next project to work on then. This is the drivers side running board, the passenger side is soaking in milkstone rinse to remove the rust while I work on this one.
Where I have the outer yellow tape is what shows past the body when mounted and the inner tape is what will show with the door open.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240318_123312-jpg.423145/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240318_123312-jpg.423145/Here is a more overhead view. Originally these had rubber covers on them which is why they have all the little holes in them. I have been on the fence about just installing new rubber covers or smoothing these out and just painting them. It would be easier to just install new covers but I am not crazy about the look so I think I am going to take the plunge and start welding up the holes and go the smoothed out route with maybe some kind of step pad in the middle. If that doesn't turn out well I can always just install covers later, as it shouldn't hurt anything if the covers are on a smoother running board.
Brian :cool:

TrifiveRichard

03-20-2024, 05:49 AM

Custer55

03-20-2024, 07:34 AM

Looking good, Brian. For an idea on running board rubber, here's one we used on the 49 F-1 pickup we built some years back. They are aluminum strips with rubber inserts. They have held up well over the years.

14054

Thanks for the idea for the running boards. That would like nice!
And nice truck, I remember my dad having a couple of dump trucks and a stakebed of that vintage when he had his plumbing and excavating business. :cool:

Custer55

03-27-2024, 05:39 PM

Work on the running boards continued this past week. I made my tray for the Milkstone rust dissolver big enough to fit one running board at a time so while I had the passenger side soaking I did some work on the drivers side.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240319_124155-jpg.423860/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240319_124155-jpg.423860/I started by welding up a bunch of the small holes which I think are in there to help the running board covers adhere better. I had started welding up the holes on the bottom edge and then decided I didn't like having the little bump out at the bottom edge.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240319_122231-jpg.423861/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240319_122231-jpg.423861/So I started hammering the bump out from the backside to eliminate the bump. With the running board clamped to my welding table I used a caulking tool I made (on the left) and then an air hammer with my home made planishing die to smooth it all out better.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240321_142935-jpg.423862/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240321_142935-jpg.423862/Hard to tell in this shot but I have the bottom edge smoothed out and all the holes welded shut. The holes were easier to weld shut this way so that was a plus. It will still need some body filler but it should look much better when done. So at this point I pulled the passenger side out of the rust dissolver and put this one in to soak for a while.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240321_152848-jpg.423863/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240321_152848-jpg.423863/With about 85% of the rust cleaned off, the passenger side board should be easier to work on. Less dust anyway, but it looks like this one will need more patches for the rust.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240322_160903-jpg.423864/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240322_160903-jpg.423864/After flattening out the bottom edge and welding up the holes where the metal was still solid I marked up where I will need to make patch panels for the areas that the rust pits have become small rust holes. Pretty close to not being worth fixing but I will see how it goes.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240323_151426-jpg.423865/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240323_151426-jpg.423865/I started with a patch on the rear outside corner. On this one I left the lower edge intact and spliced the patch into the face only of the hem at the bottom.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240325_122341-jpg.423867/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240325_122341-jpg.423867/Then I decided to recreate the bottom edge hem on the patch panels to eliminate one long weld seam. Unfortunately this meant the patch panels would have to be shorter as 10 1/2 to 11" was the maximum I could bend in the 16 gauge I was using to match what the original running boards are made from. To make the hem I 1st bent about a 90 degree angle in the panels.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240325_123433-jpg.423868/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240325_123433-jpg.423868/Then I hammered them over to create the hem similar to originals just without the little jog just above the hem. Good thing these won't show on the finished product unless someone sticks there head under the running boards. The car should be plenty low enough to prevent that from happening!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240324_130801-jpg.423866/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240324_130801-jpg.423866/And here is the first section tack welded in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240327_102556-jpg.423869/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240327_102556-jpg.423869/And here it is with 5 more patch panels tack welded in place as well as a small patch where it will meet up with the front fender. Lots more work left on this one but it will look much better when done and I am pretty sure the drivers side will not need near as much rust repair.
Brian :cool:

Custer55

04-11-2024, 08:40 PM

Work continued on the passenger side running board over the last couple of weeks. Not a lot got done as I was down in Central IL the past couple weekends visiting my son.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240328_162418-jpg.425260/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240328_162418-jpg.425260/I got a couple more patch panels fitted up and tack welded in place on the inside edge. Most of this will not show unless the door is open and some of not even then as it will be underneath the body but at least it will be solid metal now.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240402_125925-jpg.425261/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240402_125925-jpg.425261/And another one fitted up ready to tack weld in place. This area was in bad shape as it is where one of the braces are located which caused a lot of rust between the brace and the top of the running board.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240403_120633-jpg.425262/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240403_120633-jpg.425262/This is the last patch to make. Here I have it shaped pretty close so time to cut out the old rusty metal and fit it up.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240403_120729-jpg.425263/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240403_120729-jpg.425263/This is one of the braces I removed which shows the running board is not just a flat piece and does have a bit of a curve to it.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_134739-jpg.425264/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_134739-jpg.425264/All fit up and ready to start tack welding in place. This one took a while to get the fit right but I got it pretty good all the way around.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_145039-jpg.425265/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_145039-jpg.425265/Tack welded in place. I just did small quick tacks not worrying about weld penetration to keep the panel from moving around as I welded it in place.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_145057-jpg.425266/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_145057-jpg.425266/View from the backside shows the tack welds are just enough to hold the panel in place. I will make sure the welds get full penetration when finish welding the seams. Also note the temporary brace to keep everything in alignment when cutting out the old metal.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_162059-jpg.425267/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240404_162059-jpg.425267/And here it is with all the patch panels tack welded in place ready for a bunch of welding up and grinding out all the seams. I got started on that the last couple of days but still have a ways to go. Almost 12 feet of weld seam to go if I measured right so that will take a while.
looking better and better every day though and by the time I get both sides done the weather should be nice enough to start spaying some epoxy primer!!
Brian :cool:

BamaNomad

04-16-2024, 06:19 AM

That old Ford is getting 'newer' and newer, Brian!! It should one of the most solid old Fords around once you get done! :)

Gary

bigblock

04-16-2024, 06:38 AM

Nice post and great work as always.

Custer55

04-21-2024, 05:51 PM

That old Ford is getting 'newer' and newer, Brian!! It should one of the most solid old Fords around once you get done! :)

Gary

Nice post and great work as always.

Thanks guys,
I think I am pretty close to being done fixing all the rust!!

Custer55

04-21-2024, 06:45 PM

I spent a few days of welding to finish the passenger side running board so I have had my fill of welding and grinding for a while!!

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240412_113943-jpg.425901/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240412_113943-jpg.425901/With all the outside edges welded up I started with an easy patch to finish up the weld seams.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240414_113541-jpg.425902/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240414_113541-jpg.425902/Then I worked my way from front to back doing 3 tacks at a time and then grinding them out as I went. This area will need some work to straighten out some distortion as I expected being a very low crown area.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240414_154826-jpg.425903/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240414_154826-jpg.425903/With this patch fully welded all that was left is the seam from front to back on the front edge.

https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240419_101007-jpg.425904/https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240419_101007-jpg.425904/
After finishing the weld seam on the outside edge I spent the better part of a day planishing weld seams, hammer off dolly work, some stretching and shrinking on the flange that bolts to the frame, and working it with the shrinking disc to get it to this point. Far from perfect but it should look good enough with a thin coat of fiberglass reinforced body filler. At least it will look much better than what I started with without breaking the bank.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240418_124648-jpg.425905/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240418_124648-jpg.425905/And here I have the braces plug welded back in place so this one is done other than a coat or two of body filler.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240420_144440-jpg.425906/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240420_144440-jpg.425906/After sandblasting both running boards to get rid of the last bit of rust that the Milkstone rinse wasn't taking off I started on the drivers side running board. This is the only area I am making a patch for on this one. I had to weld up a few more holes and there was some deeper rust pits to weld up but overall it is in better shape than the passenger side was.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240420_144408-jpg.425909/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240420_144408-jpg.425909/Here is the patch I made to repair this area. I had to tip the flange over as it has a slight curve to match the frame rail in this area. This was a pretty flat area but sometimes the flat ones are harder to get done than the ones with a bit more shape to them. This one ended up with a slight twist probably from tipping the flange so it fought me to get it to lay right.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240420_150218-jpg.425910/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240420_150218-jpg.425910/With the patch being in the middle I welded in a piece of flat stock to the flange to keep it from turning into a mess when I cut the old metal out.

https://www.trifivechevys.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240421_151106-jpg.425911/
https://www.trifive.com/cdn-cgi/image/format=auto,onerror=redirect,width=1920,height=192 0,fit=scale-down/https://www.trifive.com/attachments/20240421_151106-jpg.425911/And here is where I left off today with it all tack welded in place. After grinding all the tacks flat I had to do a bit of planishing on the tacks and the area to the left of the patch to get rid of a slight oil can. Probably got that because I never did get the patch to lay perfectly flat. Just need to finish welding the seam then hopefully not to much planishing and hammer and dolly work to get it ready to replace the braces and smooth it out with body filler.
Brian :cool: