All plug welds punch and was about ready to start welding this on
Then I remembered there was one more loose end to tie up. Had to repair the lower corner of the suspension flange with some heavy gauge.
All set. The end of the new flange has to have something to hang onto. Also cleaned and remove the remains of the old "K" brace on this back corner.
I can finally begin welding this on.
Plug welded and finished out the joint along the bulkhead.
Sticking with my plan I'm going to leave everything ahead of the bulkhead wall loose until I get the front beam squared. That set screw at the front will have to do until then.
Joint seam along the bulkhead finished out smooth. Onto stitching up the joint along the new lower flange. That next; Going to be a long one.
Thanks for looking.
Justin
Late 1959 S/R coupe project # 108625
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Re: Late 1959 S/R coupe project # 108625
Thanks for looking.
Justin
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Re: Late 1959 S/R coupe project # 108625
This forward corner of the cockpit weld finished and completed. Gas weld detail at the leading edge of the bulkhead flange replicated along the way. This small portion ready to accept a new floor pan. Small area but it was a win that day. Moving rearward to continue the rest of this flange repair.
The rest of this run welded up and dressed. Lap joint details replicated carrying over the lines.
Same treatment for the backside.
I'll close and add the new gusset floor once the front beam issue is addressed.
Another mock up with the new closing panel just to see.
Next section runs the entire length all the way back under the heater tube elbow and embossment detail. However, the new replacement section isn't that long which is just as well as there is a lot of work ahead to repair in and around the elbow.
I'm going to the make the break under this outer lap joint. A perfect place to quit as it will be concealed and supported under this lap panel.
New section overshoots this eventual joint by only a couple of inches so its almost the perfect answer.
Original flange(X) is the same width as the standard issue back here so all I need to do trim away the excess.
Like before cutting just at an inch above the flange line. This portion is actually still good all the way down the flange itself but its got to be weld repaired somewhere so I might as well keep the repair uniform.
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Re: Late 1959 S/R coupe project # 108625
Saved as much of the original vertical wall as I could.
Section removed after carefully cutting around and breaking loose from the bulkheads. Prepping new section to fit next.
New section cut to basic length for a flush fit.
Now positioned for needed flange height.
Ready to etch my final cut line in and trim.
Cut to final width and clamped into position with a good tight joint. Begin tack welds.
Securely tacked
The end shape trimmed to continue that Delta-V relief shape.
Quick paper template as now is a good Time to fill that hole.
Lap patch all welded and dressed.
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Re: Late 1959 S/R coupe project # 108625
thanks for looking.
Justin
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Re: Late 1959 S/R coupe project # 108625
Impressive as always!
Antoine
Antoine
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Re: Late 1959 S/R coupe project # 108625
Thanks once again Antione.
New door well tray/floor installed. Just about ready to tack this in. I wanted to as much of that secondary wall as I could but as it stands now its in my to get a clean shot at the most inner part of the weld joint so no choice but to cut a little higher or lower in this case. Wall trimmed back just enough and began stitching it in. Nice getting more structure back in there. Begin template for the new inner splash pan/closing wall. Flange of the new pan will eventually join onto it. Ideally I would have had the weld joint run through the middle of this flange to both conceal and support it but the rust went just a little higher on this one. Eventual wall patch should butt up nice and tight against the new pan.
Secondary closing wall repair patch. Able to use the remnant section left over from the front bulkhead wall flange repair from earlier. Folded and trimmed to basic shape. Final trimming and shape all but there. Final trimming on that butt joint eventually dialed in with plug weld holes punched. Ready to weld. Very tricky patch as the flanges come in at specific angles and the wall itself has a slight lean to it making dialing in all the lines for a clean fitment all the more difficult.
New door well tray/floor installed. Just about ready to tack this in. I wanted to as much of that secondary wall as I could but as it stands now its in my to get a clean shot at the most inner part of the weld joint so no choice but to cut a little higher or lower in this case. Wall trimmed back just enough and began stitching it in. Nice getting more structure back in there. Begin template for the new inner splash pan/closing wall. Flange of the new pan will eventually join onto it. Ideally I would have had the weld joint run through the middle of this flange to both conceal and support it but the rust went just a little higher on this one. Eventual wall patch should butt up nice and tight against the new pan.
Secondary closing wall repair patch. Able to use the remnant section left over from the front bulkhead wall flange repair from earlier. Folded and trimmed to basic shape. Final trimming and shape all but there. Final trimming on that butt joint eventually dialed in with plug weld holes punched. Ready to weld. Very tricky patch as the flanges come in at specific angles and the wall itself has a slight lean to it making dialing in all the lines for a clean fitment all the more difficult.
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Re: Late 1959 S/R coupe project # 108625
Secondary closing wall patch continued:
Would have been impossible to repair this area cleanly with the hinge boss in the way.
Getting ready to weld that inner vertical flange section from the outside. Loosened the rest of it up to ensure a tight fit. A lot of planning ahead had to be done as its almost impossible to dress any weld slop down in that deep corner.
New secondary wall pretty much set and dressed. Had a really hard time reaching down into that corner but going to leave well enough alone for now.
Onto the new end cap. A little tougher to work with 18 gauge but now that I have it on hand I want to try and make most all "chassis" related components from this instead of 20 gauge.
Cut to basic and slightly oversize shape.
Rough mock up with the new longitudinal section to trim back a little closer. That new simonsen piece is made of 20 gauge which I'm not really thrilled about being such an integral component of the "frame" but we have the triangulation of the roof so it should live.
I will however reinforce it where I can.
Begin rolling in that curved leading flange detail.
Final trim and shape along with all the plug weld holes added. Ready to mount for the final time.
Carries on the flange line from the OG section.-
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Re: Late 1959 S/R coupe project # 108625
Splash pan repair continued:
Thanks for looking.
Justin
Inner wall and overlap details carried on here as well.
One more test with the long just to make sure before I started welding.
I'll add in more plug weld holes before I join these together for the final time.
Begin Plugging and stitching it on.
Fully welded and dressed
Relieved to have the heavy lifting completed in the confines of this corner.
Marking for the eventual spot weld details and the final splash pan patch overlay after the longitudinal cavity is fully welded and all closed up.
Gone as far as I can up here for now.
Onto the back half next. Should be fun. Thanks for looking.
Justin
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Re: Late 1959 S/R coupe project # 108625
Began planning the repair in and around the heater conduit.
While this rear closing wall is in mostly solid shape it is in my way.
I hate to disturb it but its going to have to come out to get a clear shot at the end of the tube.
Cutting just enough of the rear closing wall free for now.
Hated to do it but things got immediately accessible. I'll get the rest of it out later.
Begin peeling this onion by carefully removing each layer of steel or at least what is left for info and templating purposes.
Bottom outer embossed layer which is directly welded to the end of tube cut free first exposing the second layer.
Carefully removed the remains of this second layer. Again for copying purposes.
What is left is the remains of the inner most flange/wall run that welds to the end of the inner exit tube section. To the right of it are heavy gauge angle flanges off the torsion housing that were beefy enough to have just survived. I think, I'll know more once I start cleaning this area up.
Inside view that inner most wall and as you can see the rot runs deep.
To get a clear shot all of that will require the elbow of this conduit to be removed. No surprise of course.-
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Re: Late 1959 S/R coupe project # 108625
A couple more layers to go and would be touching bottom on this repair. That next...
Thanks for stopping by.
Justin
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Re: Late 1959 S/R coupe project # 108625
Touching bottom with this corner repair.
Thanks for looking.
Justin
While planning out this most inner flanged wall I did want to replicate the details like this stepped overlap.
However this rust hole was really beginning worry me as I wanted to know what the rest of it looked like beneath this flange.
Just couldn't leave it so I cut that heavy overlapping flange to find out.
Much to my relief not a whole lot. The wall just ends with no attachment between the two which was surprising but nice as it made my life a little easier.
Getting that last overlap out of the way now gives me a clean shot at the entire section where the rot has gone through.
Wall remains carefully harvested for the pattern.
Now past all the unsavable metal; I've officially touched bottom. Building this area back up from here.
Making copies of all these layers next.
Inner most flange/wall first from 18 gauge
Cut to basic shape. more on this later...Thanks for looking.
Justin
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Re: Late 1959 S/R coupe project # 108625
First new corner repair panel going in.
Thanks for looking.
Justin
Fine trimming and fitment next.
Dialing in the correct flange height. It eventually mounts to the inside of the outermost flanged wall
which needs to be a smooth and tight fitting continuation off the end of that new section I welded in earlier. Remnant flange helping to determine that here.
Tube opening had a small lip to the inside most of the way around so one was added to my copy.
Checking the height and fitment back here against that heavy gauge overlap from earlier.
Then a quick check also with the next layer that will eventually go over top of those two. Everything sandwiched together as nice as I could tell.
New repair section finally positioned and tacked in.
All stitched in and onto the next layer.
I was going to make a new piece here but after a quick dunk in acid it was clear there was enough meat left to reuse. Ground back the shoulder to expose more of its lead. Spaced to compensate for cutting wheel thickness.
Back into original position. Cleaning up the weld joint next then its onto the next layer.Thanks for looking.
Justin
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Re: Late 1959 S/R coupe project # 108625
Thanks for Looking.
Justin
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Re: Late 1959 S/R coupe project # 108625
Begin hammer form
Thick heavy gauge plate I have on hand will make for the perfect base/step for the embossed collar detail. Cleaned the end of the tube so I could trace out that needed shape.
Paper template with the shoulder I'm looking for. Outlined on the steel and would carve it out next. A total pain in the ass but worth it as I have to do the same repair to the other side; So its a "two-fer"
Original tube section was small enough for my acid bath so it soaked overnight. Wish I could clean the rest of it like this but I'll take what I can get.
Hammer form cut out and shaped. Two holes were added so I could secure the work to it.
After a quick test with some 20 gauge I realized I needed more relief height so I added this strap stock to the back for a touch more draw.
Basic relief shape I hope to achieve. That thick stock was a bitch to cut out and shape so I was praying it wasn't in vain.
Section of 18 gauge all bolted up
and ready to begin adding in that relief shape.
Started working it in cold to get a feel for it.
Certainly not as forgiving as 20 gauge so this was a first of many rounds of heat was applied to get it to take the shoulder.-
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Re: Late 1959 S/R coupe project # 108625
Thanks for looking.
Justin