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  #31  
Old 11-02-2017, 07:37 PM
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Kerry Pinkerton Kerry Pinkerton is offline
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I repaired some Corvette C4 door frames a few years back. Difficult shapes.
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  #32  
Old 11-02-2017, 11:31 PM
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Hi Mike
Thanks , as for the welding stay tuned in, I'll get to that soon.

The rust was so bad in some areas that I had to measure and pattern off the other side of the car.

Here is the section that fits over the door (6). Started with a pattern, cut out a blank, then layed out and tipped the first flange.

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(4) is curved in two directions so tipping, shrinking and stretching were required. The top bend was made first, then shrinking was performed to get the horizontal arch. Next marked the second bend and tipped it. Lastly the upper flange was stretched and the lower flange was shrunk, to match a pattern made off the drivers side door opening.
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  #33  
Old 11-22-2017, 11:38 PM
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This is the next section of the door frame that I made. I thought about a number of ways to do it, but since it was all straight bends the simple steps are as follows.
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I already had a offset die made for a former project that was the .140 required.

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I forgot to take a pic of the part when the offset was formed. Note the quick and dirty back guide.

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My home built brake worked for the first bend.

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The next bend could not be done with my brake, but the powered tipping wheel worked great.
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Note the joggles ( offset) are not the same size.
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Now to form the end to the rectangle depression.
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Found a piece of stock that matched the channel, then used a hammer with chisel head, and a mallet to make the joggle.
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After TIG welding and planishing/ grinding.
Later steve
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Last edited by Steve Hamilton; 11-23-2017 at 10:09 AM.
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  #34  
Old 11-23-2017, 04:51 AM
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Thanks for showing the steps Steve.
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  #35  
Old 11-23-2017, 06:49 AM
RockHillWill RockHillWill is offline
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Clever use of tools and tooling. Nice work!
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  #36  
Old 11-23-2017, 01:00 PM
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More steps needed to complete this section. Mocked up some parts to see the big picture. Layout and tip of the first bend not shown.

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Layout of the tip and cut lines, just a little extra for final trim after all sections are welded together.
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Made the cut and stretched the flange a little to match the arc on the original part. I used the stretcher, but could have used any type of linear stretching tool. A rather long flange depth to stretch this way but I got the needed shape.
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The next bend needs to be parallel to the last one so a brake would not work for that, the power tipping tool (short depth bead roller) was used.
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The narrow tip wheel is on the top and a ridged nylon (plastic) for the lower. The first pass is a firm pressure to press a crease in the metal. Then back the pressure off for the next passes. Lift up on the outside edge of the part and with each pass the flange will bend up a few degrees.
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Due to the shape or the upper wheel you can not get the bend to 90*, so either a hammer and dolly, or a lower wheel with a V notch is needed to finish the bend.
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That section is now done !


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  #37  
Old 11-23-2017, 02:12 PM
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Got a few of he simple sub sections made. Rather straightforward so will just show the pics for now. GM spotwelded all the pieces together and used offsets and overlapped them, which made it more challenging to make. I tried to drill and screw the panels for alignment prior to drilling or grinding out spot welds which made assembly accurate.


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Last edited by Steve Hamilton; 11-23-2017 at 02:18 PM.
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  #38  
Old 11-23-2017, 02:36 PM
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Another simple panel, well if you have all the information needed. The joggle was completely rusted away, so had to pattern off of the other side of the car.
The notch that shows was not needed for any obvious reason. I think just to align parts when spot welded at the factory. Customer and I decided to not include it.

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  #39  
Old 11-23-2017, 07:25 PM
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Steve, the part you put an arc on and then tipped the same flange, does it still keep the same arc even though no stretching had been done in the section not tipped?



Was just wondering if you have to over stretch a bit to compensate?
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  #40  
Old 11-23-2017, 09:28 PM
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Thanks for the pics & tutorial, Steve.

My car needs some rear window frame & trunk perimeter rust repair with many similar stepped & curved shapes. This thread is a very big help.
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