BUILD THREAD “The Juggernaut”

oldsofb

Royal Smart Person
Supporting Member
Dec 7, 2007
1,384
4,014
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Maryland
Do you think the round stock flexed when welding and drew the arch closer together?

I agree with your assessment on having the right attitude. I've done some of my best fabricating having to fight back from a project that went off script. Good work there!

Hutch
 
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Sweet_Johnny

Has A Face For Radio
Supporting Member
Oct 4, 2022
648
1,175
93
Wichita, Kansas
Nice save, it looks great and after you finish it nobody will ever know it gave you any trouble. As has been mentioned those are the moments that test your sanity, patience, and ingenuity.
 
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liquidh8

Comic Book Super Hero
Looks great! Sucks for the setback, but as you stated, it's all in the attitude! At least you didn't leave knuckle marks in it, haha
 
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Rktpwrd

Builder of Cool Shjt
Supporting Member
Feb 2, 2015
4,166
23,915
113
Calgary, Alberta, Canada
Driver’s side flare is fully welded in around the arc, it was looking good after the welds were all ground down, but before the hammer and dollying was done.

IMG_3897.jpeg


After I took the hammer and dolly to it and started smoothing out the lumps, it quickly became apparent that I had too much metal right in the middle which manifested itself as a big outward lump that wouldn’t flatten out no matter what I did. Working the area with a shrinking hammer, plus several quenches with a MAPP gas torch and a cloth soaked in ice cold water didn’t do much to rectify the problem either.

I was about to cut the entire area out and replace it with fresh shaped metal, when I remembered a little trick that worked great for us on a similar problem on one of Mike’s ‘57 Chevy quarter panels. I cut a cross through the middle of the bulge with the death wheel (cutoff disc) and flattened out the 4 corners that it created. The cut allows the extra metal places to go, and will close up the cut lines slightly as the metal flattens out.

Once the 4 corners of the cuts were flattened out, I clamped one of my extended length C clamps right in the middle, and slowly and carefully welded up the 4 cut lines of the cross working from the outside in. Once I had welded and ground everything I could access with the clamp in place, I removed the clamp and finished it off.

No pictures of this process, but when the dust settled, it was all good - no more bulge.

IMG_3898.jpeg


Since that went so well tonight, I had a little extra time to start making the first of the two end pieces with the shrinker/stretcher and getting it fitted into place. This is the back one, closest to the door:

IMG_3900.jpeg


IMG_3899.jpeg


We’re very close to Christmas now, so life and family priorities are starting to cut into the available time over the next couple of days. I might get a little time on Saturday to try and make a bit more progress, but that’s about it until after Christmas Day.

After that, I’ve got the entire week between Christmas and New Year’s off, so Mike and I will be spending a couple of days working on each other’s cars back and forth. I anticipate that the last of the fabrication and welding will not only be done in this time frame, but I should also be able to get started on the filler and bodywork on both fenders as well.

There likely won’t be another update before Christmas, so a very Merry Christmas to everyone, all the best to you and yours!

D.
 
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mclellan83

Comic Book Super Hero
Jun 27, 2017
4,245
9,434
113
Pgh, PA
Driver’s side flare is fully welded in around the arc, it was looking good after the welds were all ground down, but before the hammer and dollying was done.

View attachment 232669

After I took the hammer and dolly to it and started smoothing out the lumps, it quickly became apparent that I had too much metal right in the middle which manifested itself as a big outward lump that wouldn’t flatten out no matter what I did. Working the area with a shrinking hammer, plus several quenches with a MAPP gas torch and a cloth soaked in ice cold water didn’t do much to rectify the problem either.

I was about to cut the entire area out and replace it with fresh shaped metal, when I remembered a little trick that worked great for us on a similar problem on one of Mike’s ‘57 Chevy quarter panels. I cut a cross through the middle of the bulge with the death wheel (cutoff disc) and flattened out the 4 corners that it created. The cut allows the extra metal places to go, and will close up the cut lines slightly as the metal flattens out.

Once the 4 corners of the cuts were flattened out, I clamped one of my extended length C clamps right in the middle, and slowly and carefully welded up the 4 cut lines of the cross working from the outside in. Once I had welded and ground everything I could access with the clamp in place, I removed the clamp and finished it off.

No pictures of this process, but when the dust settled, it was all good - no more bulge.

View attachment 232670

Since that went so well tonight, I had a little extra time to start making the first of the two end pieces with the shrinker/stretcher and getting it fitted into place. This is the back one, closest to the door:

View attachment 232671

View attachment 232672

We’re very close to Christmas now, so life and family priorities are starting to cut into the available time over the next couple of days. I might get a little time on Saturday to try and make a bit more progress, but that’s about it until after Christmas Day.

After that, I’ve got the entire week between Christmas and New Year’s off, so Mike and I will be spending a couple of days working on each other’s cars back and forth. I anticipate that the last of the fabrication and welding will not only be done in this time frame, but I should also be able to get started on the filler and bodywork on both fenders as well.

There likely won’t be another update before Christmas, so a very Merry Christmas to everyone, all the best to you and yours!

D.
Can't show that process to keep your cover
Christmas GIF by Coolidge Corner Theatre
 
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Longroof79

Rocket Powered Basset Hound
Oct 14, 2008
12,174
9,776
113
Gainesville, Fl
Merry Christmas and all the best for a Happy, healthy New Year to you D.
Thank you for sharing your skills and all that you've accomplished so far.
We enjoy your detailed thread. (y):cool:
 
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Tony1968

Royal Smart Person
Supporting Member
Jul 1, 2018
2,323
5,118
113
NW Indiana
Merry Christmas to all. I don't know how I've missed the last month of progress 😕 but I'm all caught up now and WOW. Just amazed at the creativity and resolve. Don't know why it surprises me. Awesome work D.
 
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