My SC coupe project. Made by hand…again.
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
Hey Phil,
That piece you don't recognize is NOT original. Good eye. I added it to strengthen this area since its prone to dishing in. Dimensions aren't critical, but I believe its about .5" tall and spans to both sides. This brace is notched to go over the weld nut. I welded the brace directly to the weld nut and on both side walls. This puts the load path directly onto the added brace which transfers it to the vertical channel walls. To make it even stronger, I could have used an L shaped brace with the return flange facing the weld nut.
Thanks Justin, Yes I made the whole enchilada....twice. Makes you miss your carrera metal working days right? I'm always trying to catch up to you!
That piece you don't recognize is NOT original. Good eye. I added it to strengthen this area since its prone to dishing in. Dimensions aren't critical, but I believe its about .5" tall and spans to both sides. This brace is notched to go over the weld nut. I welded the brace directly to the weld nut and on both side walls. This puts the load path directly onto the added brace which transfers it to the vertical channel walls. To make it even stronger, I could have used an L shaped brace with the return flange facing the weld nut.
Thanks Justin, Yes I made the whole enchilada....twice. Makes you miss your carrera metal working days right? I'm always trying to catch up to you!
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
More work on the door today trying to make the door bottom fit. Believe it or not the old door bottom wasn't that bad, so it made a good pattern. C cars had this unique stamping pattern and my replacement panel is an old one from Stoddard.
First, I measured the amount of bow where the skin wraps around the door bottom. Its important that the door isn't flat at the bottom. Its about 1/8" - 3/16" on both ends. Some of the impressions weren't exactly like the original. I'm committed to doing my best on this car, but even I think this next step is overkill. Then, the hole locations were checked versus the original. So, I moved them. Door bottom finally installed That was a entire day spent prepping a replacement part that I thought would be good to go. O well, kind of reminds me of engine building. Always check all the parts before assembly.
First, I measured the amount of bow where the skin wraps around the door bottom. Its important that the door isn't flat at the bottom. Its about 1/8" - 3/16" on both ends. Some of the impressions weren't exactly like the original. I'm committed to doing my best on this car, but even I think this next step is overkill. Then, the hole locations were checked versus the original. So, I moved them. Door bottom finally installed That was a entire day spent prepping a replacement part that I thought would be good to go. O well, kind of reminds me of engine building. Always check all the parts before assembly.
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
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Re: My SC coupe project. Made by hand…again.
Excellent work tom.
I'm doing my doors as well. Same problem with my piece. Just tacked in the bottom piece tonight! May I ask, how did you drill the four drainage holes on the bottom seam so nicely?
Frazer Carless had kindly lent me his door jig which he made. It sets the bottom curve. I'll post some pics of it...
I'm doing my doors as well. Same problem with my piece. Just tacked in the bottom piece tonight! May I ask, how did you drill the four drainage holes on the bottom seam so nicely?
Frazer Carless had kindly lent me his door jig which he made. It sets the bottom curve. I'll post some pics of it...
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
Hi Roland,
Thanks, and please post some pics of that door jig and your door for that matter! Seems like a great idea. I made a jig that defines the curvature going from top to bottom back when I did my other door a long time ago.
There really isn't any special trick to making those drain slots. It was tedious, but here's what I did.
a) TIG Weld a tiny patch where the hole shouldn't be
b) Sand smooth
c) Brush dychem layout fluid where the new hole goes
d) trace/sketch the new slot with a very fine scratch awl
e) center punch the other end of the new hole and drill a tad undersize
f) Run a carbide burr on a dremel to "connect" the holes.
That's it! and I got a lot of practice. They key is to get a good burr especially when tackling welds. Mine was ordered from Mcmaster Carr but I don't remember the part no. Its shaped like a tear drop.
The holes on the stoddard part were way off relative to stamped reliefs. If someone from Stoddard is listening, I'm happy to send my original part in to their QA department for a small parts credit
Thanks, and please post some pics of that door jig and your door for that matter! Seems like a great idea. I made a jig that defines the curvature going from top to bottom back when I did my other door a long time ago.
There really isn't any special trick to making those drain slots. It was tedious, but here's what I did.
a) TIG Weld a tiny patch where the hole shouldn't be
b) Sand smooth
c) Brush dychem layout fluid where the new hole goes
d) trace/sketch the new slot with a very fine scratch awl
e) center punch the other end of the new hole and drill a tad undersize
f) Run a carbide burr on a dremel to "connect" the holes.
That's it! and I got a lot of practice. They key is to get a good burr especially when tackling welds. Mine was ordered from Mcmaster Carr but I don't remember the part no. Its shaped like a tear drop.
The holes on the stoddard part were way off relative to stamped reliefs. If someone from Stoddard is listening, I'm happy to send my original part in to their QA department for a small parts credit
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
Ugh, difficult day on the rear door bottom. Everything turned out fine, but I was just off today, kept making mistakes and this just took longer than it should have.
If this had been a more difficult repair, I would have just walked away. But I wanted to get this done, so here it is. Sorry there are no progress pictures, just the finished repair. Can't complain, but lots of cuss words today. I couldn't even lob the scrap in the trash can without missing. Ha ha. Luckily the welder made everything ok. Reminds me of a saying I once heard, "The difference between a welder and a machinist is a welder can fix his mistakes!"
If this had been a more difficult repair, I would have just walked away. But I wanted to get this done, so here it is. Sorry there are no progress pictures, just the finished repair. Can't complain, but lots of cuss words today. I couldn't even lob the scrap in the trash can without missing. Ha ha. Luckily the welder made everything ok. Reminds me of a saying I once heard, "The difference between a welder and a machinist is a welder can fix his mistakes!"
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
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Re: My SC coupe project. Made by hand…again.
really a great looking repair Tom! I can appeciate all the time that has gone into it so far. Doesn't get much better then what you are doing. Keep it up! Justin
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
Thanks again Justin, Trying to work on it once a week. Your panel gaps and side reflections looks absolutely perfect. Very exciting to see you inching closer to paint.
All inner door structure is complete now. Well, except the hinge. I need to order rivets and a rod to position the hinge as Phil recommended.
Still a little finish grinding to do, but starting to look like a door again. I've been playing with a tool to simulate the appearance of spot welds. I'll probably use it on the door bottom near those plug welds I made. Will share soon. Almost time for outer skin repair! Thanks!
All inner door structure is complete now. Well, except the hinge. I need to order rivets and a rod to position the hinge as Phil recommended.
Still a little finish grinding to do, but starting to look like a door again. I've been playing with a tool to simulate the appearance of spot welds. I'll probably use it on the door bottom near those plug welds I made. Will share soon. Almost time for outer skin repair! Thanks!
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
The door hinge is back on.
I used rivets like the factory did. The clinching process was the same as the tow hook for the most part and I was glad to use the same tools I made for the hook again.
Lower door skin hem being formed on my welding table with a hammer.
Hem is done. I hammered it flat with an 18 guage strip in place to simulate the door bottom. Then the hem was opened up slightly to easily fit the door.
Getting close to finishing this door! Thanks for checking it out.
I used rivets like the factory did. The clinching process was the same as the tow hook for the most part and I was glad to use the same tools I made for the hook again.
Lower door skin hem being formed on my welding table with a hammer.
Hem is done. I hammered it flat with an 18 guage strip in place to simulate the door bottom. Then the hem was opened up slightly to easily fit the door.
Getting close to finishing this door! Thanks for checking it out.
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
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Re: My SC coupe project. Made by hand…again.
WOW! Thats alot of hours! beautiful as usual Tom!
- Trevor Gates
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Re: My SC coupe project. Made by hand…again.
You're killing it Tom, nice work!
https://www.instagram.com/trevorcgates/
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
Thanks Justin, a lot of hours for sure! Slow and steady progress. I hope it will be worth it in the end. It would suck to botch the skin repair after so much love went into the door structure!
Hi Trevor, a big thanks to you too. Roll that caddy by next time you're in HB. Endless summer fun in that beast to say the least!
I saw your TIG practice on your project thread. Some good ones in there! I'm so glad that you were able to take Steve's class to "shorten the learning curve". After you get through all the boring inner chassis stuff, you will be a pro when it comes to the outer body welding. That was my plan anyway
I shot some epoxy primer on the inside of my door today while the access was good. Also injected some primer into all the seams, nooks and crannies to be followed by seam sealer too. Hope to button up the lower skin this week. I know....the moment you've all been waiting for!!! Just kidding, its really not that exciting
Hi Trevor, a big thanks to you too. Roll that caddy by next time you're in HB. Endless summer fun in that beast to say the least!
I saw your TIG practice on your project thread. Some good ones in there! I'm so glad that you were able to take Steve's class to "shorten the learning curve". After you get through all the boring inner chassis stuff, you will be a pro when it comes to the outer body welding. That was my plan anyway
I shot some epoxy primer on the inside of my door today while the access was good. Also injected some primer into all the seams, nooks and crannies to be followed by seam sealer too. Hope to button up the lower skin this week. I know....the moment you've all been waiting for!!! Just kidding, its really not that exciting
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
Hi All,
I'm going to take a break from updating this restoration journal and 356Talk as a whole to see what shakes out with the new policy changes. Registry leaders need to reconsider their decision to "pay to post" in light of the overwhelming member disapproval. So far they have just replaced web volunteers who disagree and locked topics.
Disappointing, but I will still pay the $35 for the magazine.....no biggie.
I'm going to take a break from updating this restoration journal and 356Talk as a whole to see what shakes out with the new policy changes. Registry leaders need to reconsider their decision to "pay to post" in light of the overwhelming member disapproval. So far they have just replaced web volunteers who disagree and locked topics.
Disappointing, but I will still pay the $35 for the magazine.....no biggie.
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
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Re: My SC coupe project. Made by hand…again.
Tom,
That door is a work of art (as is everything you do)! Been following along with great interest. Very disappointed to hear you may stop posting. But I understand your rationale. I too have been feeling a sense of "heavy-handedness". Just ain't as much fun as it used to be!
Take care,
DG
That door is a work of art (as is everything you do)! Been following along with great interest. Very disappointed to hear you may stop posting. But I understand your rationale. I too have been feeling a sense of "heavy-handedness". Just ain't as much fun as it used to be!
Take care,
DG
David Gensler
- Tom Perazzo
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Re: My SC coupe project. Made by hand…again.
My 356 is back home in my garage!
I bet you didn't know this would be a life long project did you?
I bet you didn't know this would be a life long project did you?
Tom Perazzo
1964 SC Coupe (under restoration)
www.ZalexIndustries.com
- Doug McDonnell
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Re: My SC coupe project. Made by hand…again.
Only 10 years ago you started this thread. Bet it seems like a lifetime ago though. What you have accomplished is amazing.
1965 356C 2000 BMW 740i Sport 1967 Honda CL77 There is never enough time to do it right, but always enough time to do it over.