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Old 08-11-2016, 01:22 PM
Stretch Stretch is offline
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Default Making a Large Bulkhead Panel with the Pullmax

So, the 1954 Microbus Deluxe I'm working on needed a new bulkhead/divider panel. Sadly, the original panel had been repaired so badly that replacement was the only option. This was a massive undertaking: The process was very long, involving casting Pullmax dies from sections cut out of the original panel. We needed no fewer than 3 sets of dies to make the original style pressings and spears. No mean feat! The original body number was in good shape, so we fully documented removing it from the original panel and Tig-welding it into the new panel. Some light planishing dressed it up so that the insertion was pretty much invisible. Now, I must stress that absolutely no body filler has been used on this panel whatsoever. We metal finish all of our panels to the highest standards to reduce the amount of bodyshop work necessary. Anyway, I hope you guys like our new bulkhead. Thanks!
Matt

First, we patterned out the bulkhead area using 3 sections of steel. We patterned one side first; then flipped it over to the other side to check the fit, which was spot on. We then were able to duplicate the other side with ease. A simple overlap of a piece of sheet metal between the two sides and scribe gave us a perfect datum.



We then overlaid the pattern on some sheet steel and marked out the outline.



We then cut the original pressings from the original panel and cast the necessary Pullmax dies.



Setting up the Pullmax.

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Old 08-11-2016, 01:27 PM
Stretch Stretch is offline
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The initial pre-stretching on the Pullmax.





The beads after forming.



Dealing with the some distortion.

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Last edited by Stretch; 08-11-2016 at 01:38 PM.
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Old 08-11-2016, 01:42 PM
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Transferring the body number.



Tig welding in the body number.



The panel almost finished.

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Old 08-11-2016, 01:46 PM
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Offering up the panel and checking fit.



Spot welding the bulkhead in place.



Busting out the oxyacetylene to replicate the factory gas welds.





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Old 08-11-2016, 01:48 PM
Stretch Stretch is offline
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Wheeling out the imperfections on the top closing panel.



Finally finished.





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Old 08-11-2016, 01:56 PM
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Nice and tidy!
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Old 08-11-2016, 02:08 PM
dwmh dwmh is offline
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Beautiful job Matt. Did you use Kirksite to cast the dies?
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Old 08-11-2016, 02:33 PM
Stretch Stretch is offline
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Sure did David. Thanks, Matt
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Old 08-11-2016, 03:27 PM
skintkarter skintkarter is offline
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Brilliant work Matt! Thanks for showing the process. Now can everybody please shut up about Pullmax's, otherwise I'm going to have to stop and make one They are a bit thin on the ground in New Zealand.
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Old 08-11-2016, 03:59 PM
Stretch Stretch is offline
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I'll source you a Pullmax Richard and ship it out to you. You'll never look back once you've owned one
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