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Thread: wagon progress

  1. #921
    Registered Member MP&C's Avatar
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    In looking through some pictures it seems I missed showing a project we did last year. A customer brought in a "Patent Idea Display". This had a battery pack inside that powered the headlights (headlight bezels not shown) and featured a rod down the bottom that would oscillate the left headlight, and I believe would flash that headlight as well (based on linkage tied to a relay inside). The control switch is actually the left half of a Model T instrument cluster.















    It has obviously had parts (hood) that went missing over the years and an aluminum flashing replacement had been added. He wanted a hood fabricated that looked more period correct, so we offered to do louvers and a faux hinge at the top.


    For the hood we used 19 gauge AKDQ, and for the louvers we are using the Diacro press brake. The louver dies weren't tall enough for the Diacro, so an adapter was used up top to make up the difference.





    Our practice punches worked fine, but the machine did not have enough depth to the vertical supports of the press brake for the size of our hood. We would need to get sketchy. Real sketchy.

    With only about half of each die in the machine, and two set screws holding on for dear life....








    https://youtu.be/2ktrqMyY2VQ





    With louvers punched, we used the highly technical argon bottle radius brake to add our hoop. next on the list was to make our hinge using a piece of 1/4" stainless tubing.











    Next, our hood needs the beltline bead to match cars of the era, and to simulate the hidden hinges for the hood sides.


    https://youtu.be/Vm47BL7zQ8g


    Our "hinge" was plug welded in place...








    Media blasted for better paint adhesion, and ready for delivery...





    Last edited by MP&C; 01-23-2023 at 04:31 AM.
    Robert



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  2. #922
    Registered Member busterwivell's Avatar
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    DAMN!

  3. #923
    Registered Member chevynut's Avatar
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    Nice fab work, but what the hell is that thing?
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

  4. #924
    Registered Member MP&C's Avatar
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    A patent idea display. The rod at the bottom oscillates the drivers side "headlight" and I believe it also flashes, based on linkage going to the vertically mounted switch. Still don't have a clue what purpose this idea was to fix, but here we are. First one I've ever seen.
    Robert



    MP&C Shop Projects-Metalshaping Tutorials


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  5. #925
    Registered Member MP&C's Avatar
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    Here's the fabrication of our hinge covers for the wagon, since the originals didn't fit well at all. Some 1-3/16 round stock was used on the magnetic brake to provide a much closer matching radius profile, and some severe stretching was done along the bottom flange and up into the radius.




























    The reverse crease was added using a dulled and rounded press brake die section as an anvil.
















    https://youtu.be/-ipNQnB4cjA


































    Much nicer look over the stock ones. While I was working on those, Jared has been prepping our stainless trim parts for polishing/buffing...









    Robert



    MP&C Shop Projects-Metalshaping Tutorials


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  6. #926
    Registered Member chevynut's Avatar
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    Nice work Robert, totally amazing. It's interesting that your rounded profile fits the body better than the two bends on the originals. They look really good. I also like the stainless dash trim. I've been considering making some custom pieces for mine too. Not sure what I want to do there but I have some ideas and my project keeps going on and on and on and on......
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

  7. #927
    Registered Member MP&C's Avatar
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    Here's the same stuff installed on the instrument cluster... Grainger sells the metal but it's in rather raw form and needs polishing.. We're basically cutting the high part of the ridges with trizact and polishing. Gives enough reflection for it to pop.


    Last edited by MP&C; 01-23-2023 at 05:55 PM.
    Robert



    MP&C Shop Projects-Metalshaping Tutorials


    Instagram @ mccartney_paint_and_custom


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  8. #928
    Registered Member MP&C's Avatar
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    Tying up some loose ends, We still need to finish the wiring at the back of the car, but in the middle of modifying the tail light fixtures for bulb relocation. To that end, in an attempt to keep grounding issues to a minimum, quick disconnect tabs are silver soldered to the tail light housings.









    Next, we started the installation of the rear power windows. The rear motors had been mocked up a couple of times and the screw holes in the plastic housings were loose/borderline stripped. So they were drilled and tapped, and 10-32 heli-coils installed for a more permanent solution.














    Once the power window track was installed, the OEM stop block for downward travel of the window was found to be useless as the window bottomed out into the wheelwell. Some delrin was cut to size, notched for a snug fit onto the track, and two holes drilled for attachment to the track. Worked well...
























    While here at the rear window, we still needed to drill mounting holes for the shoulder harness through the window garnish moldings. A 1/2-13 bolt was used to fabricate a threaded hole spotter on the lathe, complete with flats for wrench installation.














    With garnish molding positioned, a quick tap of the dead blow hammer gives an exact location for the hole.














    Next, in order that we don't leave an unfinished hole edge, a punch set was machined for the lathe, complete with stepped shoulders to prevent any movement in the jaws when pressure was applied. This will swage the hole edge for a nice inward flange...




























    And we had received our new shipment of Cubitron H/L paper from Three Mules Welding Supply for dressing out stainless, so Jared continued prepping our edge trim parts.









    Where the hemming process we used with the bead roller isn't an exacting science, we did have some variance in the gap opening that made the prepping process a challenge. In order to get more consistency in gap width, (and thus flange flatness) a new widget tool was fabricated out of 16 gauge to open up those tight spots.

















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    Last edited by MP&C; 02-13-2023 at 04:45 AM.
    Robert



    MP&C Shop Projects-Metalshaping Tutorials


    Instagram @ mccartney_paint_and_custom


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  9. #929
    Registered Member Belair-o's Avatar
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    Hi Robert,
    Thanks for posting so many details and techniques as you work on your various projects! I am always learning something by following your posts! Thanks, Doug

  10. #930
    Registered Member MP&C's Avatar
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    Thanks Doug!


    More progress on the dash inset. In order to form the outer edge trim to fit, we made an "anvil" out of 19 gauge that match the dash inset. The excess flange was trimmed in the area of the sharp bend.



















    Some heat was applied to the bend area, slight persuasion added to bend a few degrees, the area flattened to remove any puckers, and repeat.














    Then we needed to shrink the flange on the insides to match the opening. This was accomplished by squeezing the two edge trim ends together, adding a patch of heat to form a tuck, and then flatten out the tucks to provide the shrink.


















    For attachment to the dash, 8-32 press studs were installed in the inner flanges where they are also out of sight. The ribbed stainless was installed in the edge trim, then wrapped around our oxygen bottle to provide the radius.














    And a sneak peek at our trim fitted to the dash...









    Last edited by MP&C; 02-25-2023 at 08:15 PM.
    Robert



    MP&C Shop Projects-Metalshaping Tutorials


    Instagram @ mccartney_paint_and_custom


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