Late 1959 S/R coupe project # 108625

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Justin Rio
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Re: Late 1959 S/R coupe project # 108625

#196 Post by Justin Rio »

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Last of the rusted out remains in this corner finally cleaned out.
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With that I Finally touched bottom here. No more cutting only building back up.
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Slowly trimming the new piece to final shape. Remnant flange section installed to establish the correct height needed for the eventual lap joint at the front there.
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One final test mock up with what I have to make sure its all going to fit right.
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Trimmed and finally tacked in. The corner flange will be left loose for now so I can slide the eventual kick panel flange replacement underneath it.
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Moved from paper to steel.
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This standard flange repair section is a little short for this repair so I'll have add a strip on to increase its vertical reach up front here.
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Some torch heat and a wire brush was used to clean up the rust and scale as best as I can.
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finished seam welding the inner wall and added the needed strip to this next repair section.
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Installing this piece next. This photo shows exactly why I wanted get the welding done on interior wall section in first.

Thanks for looking.
Justin

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Justin Rio
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Re: Late 1959 S/R coupe project # 108625

#197 Post by Justin Rio »

Most inner flange panel installed.
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Working outward from here.
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Two vertical walls down with three more layers to go.
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Now its onto this heavy gauge flange that is actually part of the torsion tubes end housing/face here.
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As you can see after some time in the acid bath its too thin and compromised to reinstall.
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Rummaging through my scrap pile for a nice piece of heavier 16 gauge.
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New torsion housing lower flange section. Rounded up a nice little strip of 16 gauge. Basic Lower flange in at this point.
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To get the right flange profile shape I had to relief cut it and fold it individually. Planning my next cuts for shaping here. I knew I was going to come a little short on that lower tip but I figured I'd add it back in later.
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Cutting and rolling in the needed shape. Slowly getting there.
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As expected I came up a little short on that neck section so I'll just add a small piece onto the end of it.
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Section added, now completing my little bird shape. Some minor shape tweaking will still be needed as its welded in but its close enough to the original section to proceed. 16 gauge is much more involved to work with, especially tiny shapes like this. You can't cut it with hand shears nor can you bend it with any accuracy without torch heat.

Installation next. Thanks for stopping by.

Justin

Puygranier Antoine
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Re: Late 1959 S/R coupe project # 108625

#198 Post by Puygranier Antoine »

Great progress as always, thanks for sharing !

Antoine

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Re: Late 1959 S/R coupe project # 108625

#199 Post by Justin Rio »

Thank you Antione.

Repair of layer #2 installed.
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Thought I was ready but I still had some more fine trimming and tweaking to do before it was ready to tack. Also had to peel an additional strip of layers 3&4 to give me a clean shot at the weld joint.
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All but ready. I turned the lower flange a little too tight and had to relax it before I could tack weld.
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All welded in..,finally.
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Through all the bending shaping I had issues trying to get this piece to run consistent down the line while also fitting up where I needed it to. Thankfully in the end, it all lined up.
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Dressing the welds and then its onto layer #3. Back to a much nicer to work with 18 gauge.
Layer #3 install
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This is the lower gusset section that bridges across the saddle profile in the flange. Templating off of the remains of the left side and need only to flip the paper over for a right side application.
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Flange has a swoopy profile for the saddle area it bridges.
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Onto metal. Relief cut the flange for the needed curve in its profile. I'll just back fill that with weld to attach it further to the new torsion housing flange.
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New bridge section ready to go.
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Number 3 layer all welded in.
Thanks for looking.

Justin

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Martin Benade
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Re: Late 1959 S/R coupe project # 108625

#200 Post by Martin Benade »

Looking good. You are procrastinating getting those broken bolts out as much as I did for the same.😀. I really lucked out on mine though, it turned out to be missing bolts with crud in the holes, nothing broken off.
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Justin Rio
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Re: Late 1959 S/R coupe project # 108625

#201 Post by Justin Rio »

Thank you Martin. Yes, I was in no hurry to deal with those. I did start cycling them through some heat as I used my torch in around the area.
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Tempting to make this gusset a little longer but that's not the way it came.
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Dressing the welds smooth next.
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Then its onto layer #4. And again, starting to hit those twisted off bolts with some heat before I plug welded some nuts on for removal.
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This bottom section again is the remains from the right side and is placed on here backwards for the photo. Still thankful that the right side was intact enough for a reference. Working on this final wall section next.
Quick detour before installing vertical wall #4
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This lower cap which I've designated #5 for explanation purposes needs to go on ahead of the final vertical wall because its flange lap joints over top of this section.
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You can see the remains of this lap joint in the lower right. Before I can install this new cap I'll have to repair the hole in the heater tube and seal the cavity as best as I can.
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Large hole and several small pin holes back filled. Gas welding really turns the trick here for rusty thin old metal.
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Cavity slathered in epoxy and sealed as best as I can.
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New cap section made of heavier gauge sheet welded in.

Thanks for looking.

Justin

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Harlan Halsey
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Re: Late 1959 S/R coupe project # 108625

#202 Post by Harlan Halsey »

I think I would have dealt with the broken off bolts before closing the cavity. I was lucky in that mine did come out with a lot of persuasion, but it was close.

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Martin Benade
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Re: Late 1959 S/R coupe project # 108625

#203 Post by Martin Benade »

I like gas welding a lot for slow careful details, it’s great. Before MIGs got common I welded plenty of miles with oxy acetylene.
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Re: Late 1959 S/R coupe project # 108625

#204 Post by Justin Rio »

Uhm, no real advantage either way; cavity open or closed. With the heater tube and the torsion housing in place you have no shot at the back sides of the upper 3 bungs. The lowest bung offers only partial reverse access and at a very steep angle. The bolt shanks also remain shielded down inside the bung housing so direct torch heat is extremely limited at best. Had I destroyed the bung, all the work of replacement and rewelding goes to the outside. The successful extraction of these coming up shortly.

Gas welding is perfect for "soldering" very thin rusted out metal like the bottom of this tube. A MIG will just blow it out before you can put any real heat to the edges you're trying to build on.

Justin
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This Original section was the "window" I cut out to see what was actually going on in here. Its laid over to top of the new closing section to show that it replicates what was there.
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Outer skin section that lap joints over top of this newly installed #5 cap. Good for now...
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Back onto paper templates for the final vertical wall section.
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New rough cut 18 gauge section.
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My hammer form placement set and now bolted down. Beating in the relief shape next.
Hammer forming relief shape into vertical wall section #4
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Began forming it cold and went as far as I could before adding in the heat. This being 18 gauge I could only go so far.
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After several laps and rounds of heat I finally had the relief shape I was after.
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This tube originally sat off to the lower side of the relief shape.
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To determine where that is exactly , this new panel is now roughly trimmed along its top (Or the bottom in this shot) and is in the process of rough fitment to the chassis.
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Once the new panel is set into its final position. The tube section clamped to the main run will tell me where the final opening needs to be.
Thanks for looking.

Justin

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Re: Late 1959 S/R coupe project # 108625

#205 Post by Justin Rio »

repair panel #4 continued.
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Committed and initial opening cut it.
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Gradually opening it by rolling the lip inward so the end of this tube will actually fit in there. The rolled lip will eventually be seam welded to the end of the tube as originally.
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After several tries the end of the tube finally slipped in.
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Good preliminary fitment but there is still some tweaking needed to allow the tube end to swing in into alignment. Close enough to leave for now.
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I can now commit to the lower flange placement. Adding that in next.
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New lower flange heeled over.
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Once again, thank god for reference parts. I would have never thought to add in this cutout shape to the back of the flange. Still needs more trimming but good for right now.
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New flange clamped flush locking in this sections final position. The tube end still lines up like it did before.
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More fine trimming and tube end alignment and welding are about all that remains. Dangerously close to installing this on for good....but.
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before I weld the end of the tube section back on I want the ability to remove and reinstall these bulkheads for repair. That coming up next....another little detour.
Thanks for stopping by.

Justin

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Chris Davis
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Re: Late 1959 S/R coupe project # 108625

#206 Post by Chris Davis »

I'm going to bookmark this page as I suspect I'll be referring to it often once I get to this point on my car. Thanks again for the detailed photos and explanation of the battle plan Justin!

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John Brooks
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Re: Late 1959 S/R coupe project # 108625

#207 Post by John Brooks »

Chris

The entire build is at abcgt.com under restorations go and sign up.
John Brooks

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Puygranier Antoine
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Re: Late 1959 S/R coupe project # 108625

#208 Post by Puygranier Antoine »

Cool progress, well done!

Antoine

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