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Old 09-20-2019, 10:19 PM
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MP&C MP&C is offline
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Default A Pillar Rust repair/fabrication

So we've been blocking out epoxy primer, it sure is nice to be able to rotate the car where you need it instead of sanding upside down on the bottoms of drip rails.





But then you walk past the Driver's A pillar and see holes that shouldn't be there.








I don't know how I've missed this before. We did have this same repair done to the other side, I guess with the roof damage confined to that same side I must have not thought this side was suspect. Goes to show, check ALL problem areas, especially if issues show on one side.











Inside the hole has a minimal amount of surface rust, especially for 64 years old. Safe to say the damage was caused by water/dirt accumulation between the center structure (the one we're remaking) and the outer skin. Oh well, it's been a while since I've had a back up and punt moment. Glad this was found before the green kandy went on.


Starting to make the new replacement for the inside, using 14 gauge cold rolled steel.


https://www.youtube.com/watch?v=G7xV0t4WaVY


https://www.youtube.com/watch?v=0gpH2WfqWVc


Quite a bit of stretch added for the part to match the original..








Rough shaped on the MH19, tuned up a bit with body hammers, punches used as anvils, and various other implements of destruction. Trimmed and fitted:











All ready for welding.
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Old 09-20-2019, 10:22 PM
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Default

Tacked using the TIG:





video:


https://youtu.be/UixLOAZejMI





welds dressed:








Epoxy primer added:


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Old 09-20-2019, 10:23 PM
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Now to get our outer patch fabricated.. The corner is going to need a GRUNCH of shrinking.. We started on the Baileigh, but the dies are only going to get us so far. So some tuck shrinking with some heat for persuasion was used..














A tipping wheel in the bead roller was used to mark our bend line, and an upper press brake die used as an anvil to hammer the flanges over..





Some hammer action to stretch the corner flange so it will tip the full 90*


https://www.youtube.com/watch?v=_FEIEQoGzdg





I missed some in process pictures here, but various hammers, anvils, punches, and other implements of destruction were employed to give us our basic shape...








After a bit of fine tuning, it is trimmed and fitted into the A Pillar...


https://www.youtube.com/watch?v=HCDRj5uOU3s


and the windshield stainless is test fit for good measure..





The finished piece is media blasted (Barton Garnet) so the SPI epoxy primer will have a good bite. The inside is primed as a bit more preventative measure over factory....








The flange is quite small compared to what we normally plug weld, so we opted for a .169 drill bit to keep the heat away from the edge...





In order to clean he primer out the inside of our plug weld holes, we flattened and backfaced our drill bit to mimic an end mill....





Does a good job of giving us nice clean metal for a good weld..








much better....


https://www.youtube.com/watch?v=T8ajeDMzOJ0





.
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Old 09-21-2019, 05:00 AM
Larry4406 Larry4406 is offline
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Well done!

I like the use of the rare earth magnets to hold the patch piece in place for welding.
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Old 09-21-2019, 09:05 AM
cliffrod cliffrod is offline
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You never fail to impress, Robert. Great work, great post. Thanks, man.
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Old 09-21-2019, 09:53 AM
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That outside piece woulda taken me three bits to finish at least. Sweet.
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Old 09-21-2019, 11:46 AM
rookie rookie is offline
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Beautiful as always, Robert....you always make those pieces look so easy!

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Old 09-21-2019, 05:41 PM
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Great blow by blow Robert.

Do you have any trouble with the arc straying with those strong magnets?

Which build is this on?
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Old 09-21-2019, 08:38 PM
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MP&C MP&C is offline
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Thanks for the comments fellas! The magnets were primarily for holding it for fitment. I did tack it in place but quite far away from the magnets. The three used there were only 18 lbs pull, so these weren't all that strong ..


Pugsy, I could have shaved the time at least in half had I made these in multiple pieces. But unless you try making it in one piece you'll never know if you can do it, right? I really like those challenges....
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Old 09-22-2019, 06:19 AM
Antoine_P Antoine_P is offline
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As usual Robert, very impressive work, thanks so much for sharing

Antoine
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