Wagon Progress

Bob, I haven't sprayed any waterborne, but this is likely similar. It seems to have a "thinner viscosity" than the urethanes and bases that I've been used to.. It seemed to cover well, but then I was spraying black diamond over black epoxy. It laid nice and flat with minimal build..
 
Thanks!


Well, we had gotten some more sanding done......


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.....and since it was still early in the evening, mixed up some more epoxy....


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Doesn't seem like much to show, we're still sanding away....


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Got about half done with the tail gate and remembered we needed some holes drilled in the new skin for the emblem. Only issue was that I had done some spring cleaning earlier this year and the original skin with the hole pattern and location was now gone. So I sent an email to Mikey at The Stainless Shoppe, as he had an original, and he got me squared away... Thanks Mikey!


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I located the hole for the center alignment pin first, and planned on using some spotters for the remaining 4 holes... Some measurements were taken to insure the emblem was on straight, and then some "backstops" used. The spotters come in a set of various sizes, and typically you never find the exact size you need...


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These will go in some 10-24 threaded holes on the emblem. The closest size was the 1/8" spotters, so we'll need to adjust the fit..


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A couple wraps of fineline tape and we now have a snug fit so the spotters don't fall out..


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Then the emblem is located on the tail gate with the center alignment pin, then the back stops. The emblem is pressed onto the tail gate, and the spotters leave their mark on the epoxy paint finish..


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Next, the studs are installed finger tight using sleeve retainer. This will hopefully keep them from spinning inward any further risking possible damage to the chrome bezel...


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The nuts that come with the emblem are the split thread variety, and I had some threaded ones left over from the Fairlane build, that also are slightly larger in diameter, which may help out as the emblem also serves as a lift handle..


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Holes drilled and emblem fitted


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Got some more SPI Epoxy sprayed, here's the parts for my niece Katie's truck that she prepped...


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....and some more on the wagon parts....


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Well there has been a slight break in the updates, as I've been in Okinawa for about a month. Not to fear, Kyle has been plugging away on the wagon, it even has a floor in it, as you can see here...


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He did get a quite a bit of blocking done while I was gone....


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And did get some wet sanding done on a few of the interior trim pieces. Today he started on the rear floor, part of the problem with welding a flat plate is that it doesn't stay flat. The plug welds to secure the floor to the bracing beneath caused some shrinking, which resulted in the metal between bulging outward, some up, some down. Looks about like the Atlantic on a calm day.


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Today, as I was going to be wet sanding, he was going to try some torch shrinking. To better make this a one person job with minimal risk of open flame, we thought to give the "electric" torch a go.


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The plastic dust pan served as a tray to hold the wet rag, keeping it in closer proximity to where it was needed and attempt to limit the amount of water elsewhere. The results showed quite an improvement, and it's in need of some bumping at this point..


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But alas, the gas tank is in the way, so we will likely get the body back on the rotisserie here soon in an effort to get the remaining prep prior to paint completed.

Meanwhile, I was wet sanding and couldn't find the squeegee, so a trip to the local Ace Hardware at lunch, and we had a replacement. Works well, and no metal hardware on this new one to add any scratches....


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Exterior of the hood is about done...


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The flat piece was a section of 16 ga hot rolled that the owner had, hindsight and all that, it would be the last thing I'd use today. Using something that is cheap (paid for) is not always the case by the time you're done. All the extra time to clean off the mill scale, the flat that isn't, I'd say a piece of 18 ga cold rolled with bead details and we'd have been done after welding in place..
 
The last time we removed the car from the frame we used two engine hoists, which proved to be a bit cumbersome and a pain to get the frame rolled out. So I thought to try something different, this time an engine hoist at the front, and a winch in the back. Needing an anchor point for the winch, I welded this up last night to span two of the shop's trusses from overhead....

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Rear lift eyes use the tailgate hinge nut plates...


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Front lifting eyes bolt to the hinge mounts on the firewall...


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We have lift-off!


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The frame has a bit of welds left to do and we can clean it up and get it to the powder coaters...


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Dana helping out tonight...


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One way to clean it out...


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Here's the framework added to support the fuel tank and rear floor..


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This shows how nice access is for prepping, works equally well in painting..


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MP&C;n76424 said:
This shows how nice access is for prepping, works equally well in painting..

Robert, I'm no expert but that DA might work better hooked up to an air line....JK

Wagon is really coming along.
 
Bob, we're trying to save wear and tear on the compressor! :p


We're checking this week with a local machine shop to see if we can get the body media blasted... should be a much quicker prep for the epoxy..


In the meantime, the downside to plug welds and mig welds.... cleaning up all those welds..


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Kyle working on more welds..


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...and to get ready for the Tommasini class next week, we put all the 55 parts away in the paint booth...


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Getting ready for the metal shaping class at the shop this week, picked up Peter today from the airport.

Last night Kyle and I made a pedestal for some home-made stake anvils using a couple 45 lb dumbbells and some pipe/tubing, tonight made the round-head anvil and another with a holder for press brake dies....


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.....and stopped by the upholstery shop this morning to get another shot bag stitched up...


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Counting the hours!
 
Here are some of the highlights of today's class....

Peter shows how to prepare a stump for shrinking....


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Discussing weld location in panel forming....


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Using magnets to hold a paper pattern for layout....


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Wheeling, tuck shrinking and annealing aluminum sheet...


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Capturing the tuck and shrinking on aluminum sheet


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Blocking and wheeling our 19 gauge steel fender panel...


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Forming the rear corner for a Model A..


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Blocking on the sand bags and shrinking on the stump....


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Wheeling....


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Here's some of today's class projects.


The start of a scooter fender...


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Test fit of a fender panel...


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Copper work, trash can taking shape...


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Paper pattern on a roadster quarter panel....


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Using the blocking hammer to pre-stretch


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Making a pattern for the dies


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Making a pattern of luan board for a divider offset in trimming the top edge..


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What happens when a metal shaper gets around wood products...


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Trimming and filing up the top edge....


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On to the Lennox....


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Project updates for todays class:


Wiring top edge of the copper trash can..


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Roadster quarter, making dies for the upper bead detail....


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Sharpening the crease


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A bit of shrinking....


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Test fit...


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Marking for trimming the wheel opening...


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Inside radius backstop


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Scooter fender...


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Trimming...


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Prepping for Sport Coupe door skin removal


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We took a short break for a Maryland treat...


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of course, using only the correct utensils....


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Blocking the top section of the roadster quarter.....


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Final update of the class, pictures from yesterday.

Wheeling door skin for a sport coupe:

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Annealing copper wire to use as rivets:


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Cover plate for military vehicle:


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Paper pattern


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Tuck shrinking on post dolly


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Forming upper quarter reverse


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Wheel opening bead detail added


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Tipping flange with vise grips with jaws that have been smoothed...


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Stretching


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Here's a video of Peter demonstrating lead loading aluminum:


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Loading stumps for the journey to their new home..


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This class has been a blast, Peter is a wealth of knowledge and experience, and we are honored to have him share and pass this on to others. Anxiously looking forward to next year!
 
Finishing up the scooter fender..,


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Marked for trimming...


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Tipping wheel to set the side flange....


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Profile comparison, front to rear...


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.....and side to side...


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about ready for shipping to AZ.....


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.... and Kyle is dressing some welds and weld touch up to get the body ready for media blasting...


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Hey. you can still walk in this place...


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Well, more welding, grinding, and then we decided to give the roof insulation removal a try. Picked a spot and dumped on some lacquer thinner, which softened it up nicely and then made a sticky mess. So we put the putty knives aside and tried the paint scrapers..... without solvents. Dry removal was definitely better...


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Also got another shipment of shirts in from Bonehead Graphics...


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and promised the owner a modified set of spot welder tips to tackle his own wagon roof repairs...


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