All MetalShaping

Go Back   All MetalShaping > Metal Shaping Projects > Automotive Projects
  Today's Posts Posts for Last 7 Days Posts for Last 14 Days  

Reply
 
Thread Tools Search this Thread Display Modes
  #11  
Old 01-03-2018, 10:12 AM
pplace's Avatar
pplace pplace is offline
MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default

Quote:
Originally Posted by custommetal View Post
Super metalworking skills and planning. Never gave any thought to checking the weatherstrip fit when I chopped the top on my 56 chevy pu. Had to add some flat foam tape to the inside for a better seal. Luckily it was grey on grey. Thanx for taking the time to photograph and post.
George
Thank you. Still it seems as much as a person plans and thinks something out, something else will pop up down the road that you forgot!ha. As for the weatherstripping it’s nice to even have a set of “building” weatherstrip just for fitting purposes during construction.
__________________
Rush too much trying to get to the end when the end is closer when you take your time.

Dane
Reply With Quote
  #12  
Old 01-03-2018, 07:17 PM
pplace's Avatar
pplace pplace is offline
MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default

The next task on the project was shaping some new front fenders. As mentioned / shown slightly in a previous post someone had attempted to modify the fenders and wheel openings. I took this "problem" and decided to just correct the issues as well as change the wheel opening to a different shape / diameter to match the wheels better.

I created a fairly simple buck to help create the new opening that we wanted, and to help start the shape of the "S" profile created by the wheel opening / "flare" This flare actually tapers from wider in the front to narrower in the rear to account for the narrowing of the front fenders from the door to the headlights (the flare stays parallel to the wheel & tire basically"

Name:  1375802_10152003074297329_1255326346_n.jpg
Views: 924
Size:  61.0 KB

I shaped each fender out of four main pieces. Here I've got each panel shaped pretty close and am doing some final fitting & aligning.

Name:  1382044_10152003074112329_1528815147_n.jpg
Views: 874
Size:  61.6 KB

I took this opportunity to remove the bolt on front end panel seam and incorporated it into the fender.

Name:  561917_10152003073457329_1681169851_n.jpg
Views: 864
Size:  52.2 KB

Once the panels were all fitting properly I rolled the wheel lip and tacked all four panels together.

Name:  1451486_10152042992747329_1706363931_n.jpg
Views: 869
Size:  67.2 KB

The picture from the rear view shows how I now attached the fender panel to the previously fabricated fender jamb.

Name:  1458478_10152042992827329_1636498536_n.jpg
Views: 888
Size:  62.0 KB

After the main portion of the fender and wheel opening / flare were shaped I focused on shaping up the bottoms of the openings in order to blend and finish them off into the fender.

Name:  1468770_10152045007837329_1599664074_n.jpg
Views: 840
Size:  63.6 KB

Close up view showing all the panel alignment after tacking them together

Name:  1459253_10152042992717329_1426960646_n.jpg
Views: 857
Size:  69.0 KB

All sections of the fender have been fully welded and in the picture have about 85-90% of the welds planished and finished.

Name:  1455985_10152056766947329_1081460395_n.jpg
Views: 836
Size:  61.0 KB

All sections of the fender have been fully welded and in the picture have about 85-90% of the welds planished and finished.

Name:  1463132_10152056766972329_1986734888_n.jpg
Views: 840
Size:  63.3 KB

A close up showing the soft roll / radius on the wheel opening.

Name:  1467337_10152047775162329_1180905666_n.jpg
Views: 842
Size:  46.0 KB

Duplicated all this work on the passenger side as well.

Name:  1390699_10152136948857329_487340585_n.jpg
Views: 884
Size:  73.1 KB
__________________
Rush too much trying to get to the end when the end is closer when you take your time.

Dane
Reply With Quote
  #13  
Old 01-03-2018, 09:03 PM
NEB Alan NEB Alan is offline
Member
 
Join Date: Aug 2016
Location: Minden, Nebraska
Posts: 59
Default amazing

Very impressive. You have a truck that people will not see the changes you have made since they appear to be "factory".
__________________
Alan
Reply With Quote
  #14  
Old 01-03-2018, 09:41 PM
pplace's Avatar
pplace pplace is offline
MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default

Now the time came for one of the tougher portions of the project.....the doors! For numerous reasons and after much contemplation I decided it was best to build new door basically from scratch (maybe used 5% or original door in parts)

The reasons for this choice:

~The door shells were rusted and patched
~The door had been cut up quite a bit for the previous suicide hinge install
~I had to lengthen the doors on the bottom to account for not having the running boards anymore.
~The top chop hadn't done much good to the inner and outer door tops.
~The exterior skins weren't terrible, but did have some patches, shaved handles, and damage.

Besides the lower interior window opening / belt line. These are only remaining items I salvaged from the original door.

Name:  10256316_10152412776907329_1910875713627928344_n.jpg
Views: 831
Size:  48.2 KB

I thought I had more "in progress" pictures of the door shells, but this is all I see on my computer.

Here I've already fabricated the front, bottom and rear portion of the door shell and have the hinges installed and tacked checking for proper door operations.

Name:  10176255_10152412776682329_6498874816470231634_n.jpg
Views: 834
Size:  65.6 KB

View with the door open (top window opening skin is temporarily in place)

Name:  10251919_10152412776722329_3060250778742095199_n.jpg
Views: 837
Size:  70.4 KB

View of the interior side of the door shell.

Name:  1506901_10152412776752329_5407260311938402439_n.jpg
Views: 832
Size:  66.5 KB

Once I had the door shell roughed out I moved onto forming a "C" channel for the window. I created a buck (Just some MDF of the correct thickness) and made a matching set of window channels. Driver side and passenger side)

Name:  1907638_10152412776832329_3648181070587125722_n.jpg
Views: 842
Size:  70.7 KB

Here I've installed the "C" channel and have mounted the electric window setup as well as the door latch and solenoid "popper"

Name:  10251919_10152412776877329_817779955145387751_n.jpg
Views: 886
Size:  71.1 KB

A view of the passenger side at the same point, however here the mock up window is in the up position.

Name:  10462986_10152560259792329_6059121647189028534_n.jpg
Views: 827
Size:  69.2 KB

I could then start shaping the upper door shell around the window channel.

I also fit a flat inner door panel for now....waiting to trim any openings or ribs, etc. until I knew exactly where I would need access eventually

Name:  10314532_10152412776942329_7982037092379718380_n.jpg
Views: 859
Size:  59.5 KB

The exterior door top pieces were reshaped, and added to where needed. I did add new material around the top perimeter and tipped it over 90 deg. so I could hem it to the door shell when ready.

Name:  10174873_10152412777187329_7349452636852294101_n.jpg
Views: 839
Size:  78.1 KB

In the process of folding the hem over onto the door shell flange

Name:  10330482_10152412777227329_7134584593465280015_n.jpg
Views: 847
Size:  73.7 KB

Finished hem

Name:  10247306_10152412777312329_7821488133403960587_n.jpg
Views: 819
Size:  47.2 KB

Door top basically finished inside and out.

NOTE: I do not have the upper cab door jamb installed in this picture, thus the gaps around the door top (that's a story for another post later)

Name:  10269491_10152412777287329_9196454522740291562_n.jpg
Views: 838
Size:  63.6 KB

During the process I had my mock up window (correct thickness) so I could fit all the window run rubber and also made and fit the inner and outer door sweep "fuzz" so I could shape and locate the inner and outer door skins properly.

Name:  10271491_10152412777077329_836353394207112250_n.jpg
Views: 815
Size:  62.4 KB
__________________
Rush too much trying to get to the end when the end is closer when you take your time.

Dane
Reply With Quote
  #15  
Old 01-03-2018, 09:56 PM
Oldnek Oldnek is offline
Member
 
Join Date: Mar 2011
Location: Ulladulla, Australia
Posts: 1,346
Default

Very nice work you are doing, Dane, your attention to detail is outstanding.
Pretty awesome.
__________________
John
EK Holden V8
Reply With Quote
  #16  
Old 01-03-2018, 11:02 PM
pplace's Avatar
pplace pplace is offline
MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default Start of roof repair

Quote:
Originally Posted by Oldnek View Post
Very nice work you are doing, Dane, your attention to detail is outstanding.
Pretty awesome.
Thank you, I appreciate the comments.

Next up is the roof! The roof was pretty cut and spliced up from the previous chop attempt. The transitions from the roof to the edges front and back as well as into the door tops was "off" very flat in spots with no real flow.

This post will show what I had to start with and also a couple pictures of some of the pieces I shaped around the perimeter of the roof (I did save the center of the roof) I'll do another post with the actual fitting and welding of these pieces into the roof.

This "before" picture shows the numerous seams, relief cuts and welds in the roof. I can see three seams across the roof from door to door just in the front half of the alone. Several relief cuts at the top of the "A" pillar as well

Name:  10330455_10152560259677329_5533000386972807839_n.jpg
Views: 813
Size:  55.9 KB

View from the other side. Pretty much the same story, lots of seams and mis-aligned welds.

Name:  419390_10150724356182329_1728086134_n.jpg
Views: 813
Size:  75.4 KB

Even in the early stage of rough shaping the new front section of the roof you can see the "lows" from the previous welds going across the roof.

Name:  10505565_10152560261612329_6738226446522885210_n.jpg
Views: 806
Size:  62.8 KB

Here I've started to shape up new panels around the roof. Some are final shaped more than others in this picture. In this pic there is the front half of the roof panel, the "A"-pillar panel, a panel above the door top and the rear corner of the roof.

Name:  10487404_10152560261442329_6332315587461739897_n.jpg
Views: 797
Size:  75.0 KB

A view from the rear showing some of the panels taking their shape. This also shows I did a panel above the rear window (I don't recall why I made that particular piece in two halves? Split at the centerline of the cab?) I may have done it so I would only have needed to remove half the original roof piece to help maintain some structure / shape? Either way, I know it all worked out in the end!ha

Name:  10452377_10152560261262329_7518981926479756711_n.jpg
Views: 808
Size:  65.6 KB

Another pic from the rear, just a different angle. This shows the rear center portion of the roof that I was able to save.

Name:  10462667_10152560261297329_463172153519432044_n.jpg
Views: 805
Size:  63.1 KB
__________________
Rush too much trying to get to the end when the end is closer when you take your time.

Dane
Reply With Quote
  #17  
Old 01-04-2018, 03:49 AM
steve.murphy steve.murphy is offline
Member
 
Join Date: May 2009
Location: Brisbane, Australia
Posts: 650
Default

Nice work this is an epic thread. The untouched sheetmetal amount must be very small!
__________________
Steve

ærugo nunquam dormit
Reply With Quote
  #18  
Old 01-04-2018, 04:31 AM
Gojeep's Avatar
Gojeep Gojeep is offline
MetalShaper of the Month March 2015, March 2020,, June 2022,Aug 2023
 
Join Date: Nov 2013
Location: Eastern Melbourne, Australia
Posts: 2,986
Default

Excellent work. What are you using to shape most of your panels with?
__________________
Marcus
aka. Gojeep
Victoria, Australia
http://willyshotrod.com

Invention is a combination of brains and materials.
The more brains you use, the less materials you need.
Reply With Quote
  #19  
Old 01-04-2018, 05:29 AM
Kerry Pinkerton's Avatar
Kerry Pinkerton Kerry Pinkerton is offline
Administrator
 
Join Date: May 2009
Location: Near Huntsville, Alabama. Just south of the Tennessee line off I65
Posts: 8,321
Default

Very impressive work Dane. You sir are no hack!
__________________
Kerry Pinkerton
Reply With Quote
  #20  
Old 01-04-2018, 08:48 AM
pplace's Avatar
pplace pplace is offline
MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default

Quote:
Originally Posted by steve.murphy
Nice work this is an epic thread. The untouched sheetmetal amount must be very small!
Thank you very much! I'm glad I'm able to share this project with others. There was very little original metal used.....just used it as a rough "guideline" and base to start either repairing or modifying from.


Quote:
Originally Posted by Gojeep View Post
Excellent work. What are you using to shape most of your panels with?
Again thank you! Nothing too fancy here.

Homemade english wheel
Shrinker & Stretcher
Deep throat Shrinker / Stretcher
Bead roller
Metal brake
Sandbag
Hammer and dollies
Time!!

Quote:
Originally Posted by Kerry Pinkerton
Very impressive work Dane. You sir are no hack!
Thank you very much! That really means a lot. I'm 100% self taught through trial and error, research, taking ideas and techniques from what others do online, etc. I'm fairly "youngish" currently at 36 (this project was from about 2 years ago however) but have gained a large interest in shaping and forming metal over the years. When I shape projects I try to plan out according to my skill set and see how far I can get.
__________________
Rush too much trying to get to the end when the end is closer when you take your time.

Dane
Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump

All times are GMT -5. The time now is 02:42 PM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.