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  #51  
Old 01-07-2021, 07:11 PM
SATAUS SATAUS is offline
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Default Filling the 60mm gap left over from the chop



Unfortunately I found a 7mm miss match on the passenger side so I had to do a shit load of extra work to fix it .


Pattern to make sure roof goes back to correct shape after cutting into strips.








It's a bit hard to see but the roof now lines back up with the door frame.


Gap infill


Starting to tack weld roof back together.


The "TIG" not the "Stig"


Always fighting distortion.








And always beating distortion.










I had to make a special dolly to get down into the narrow part of the roof.
Mild steel and hard faced weld worked out OK.






After many hours of beating the shit out of it and filing its back in shape.


Drivers side only had a very small amount of miss match so only had to put very small slits in.






















It looked like some one had come in and jumped on the roof after welding.








And the hammering and filing starts


More Pullmax tooling








Test part just in the bench vice.














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  #52  
Old 01-07-2021, 08:09 PM
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123pugsy 123pugsy is offline
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Wow....nice.
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  #53  
Old 01-08-2021, 07:25 AM
metaldahlberg88 metaldahlberg88 is offline
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Looks awesome!

What are those clamps with the wing nuts holding together the slits? Looks like a handy addition to the shop, might need to get some myself.
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  #54  
Old 01-08-2021, 10:17 AM
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123pugsy 123pugsy is offline
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The HAZ on your long roof welds appear as a straight through pull.
Is this the case? Let it shrink and deal with it?


I hear so much of skipping around a bit here and there but not really sure if it actually helps anything.
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  #55  
Old 01-08-2021, 11:46 AM
tom walker tom walker is offline
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I'm impressed, beautiful workmanship!
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  #56  
Old 01-08-2021, 12:12 PM
chrisnz chrisnz is offline
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Cool truck. What did you lower the roof by and is it corresponding to the gap in the roofline? I'm doing the exact same model truck at the moment.
Chris
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  #57  
Old 01-09-2021, 06:59 AM
Antoine_P Antoine_P is offline
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Amazing, thanks for sharing!😍

Antoine
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Resurrecting a 60 ghia:
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  #58  
Old 01-09-2021, 02:54 PM
dwmh dwmh is offline
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I feel your pain having to undo all that work, but you made a great job of it. Well done.
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  #59  
Old 01-10-2021, 04:37 AM
Cgarside Cgarside is offline
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Fantastic work and great attention to detail - thanks for sharing
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  #60  
Old 01-10-2021, 08:52 AM
Marc Bourget Marc Bourget is offline
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Watched a Gene Winfield demo at the Santa Cruz Metalmeet and my recollection is he advocates hammering as you go, Weld about 6" and hammer, etc. (repeat)



No experience myself (why I went to the meet!) in this type of task, which requires, as Gene said, someone experienced to work the dolly, below.


Seems it would avoid the cumulative effects occasioned by a "weld it all, planish it all" approach.


Having said that, I'll sit back and collect more education!
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