|
|
Post by John Kanters on Feb 13, 2012 23:15:34 GMT -8
The LHD doesn't phase me, quite like it actually.
Already have 2 LHD 79 Convertibles and a LHD Mustang so quite used to it by now.
Did think about converting it but there's no need to in NZ so I'll leave it be, believe its a different story in most OZ states?
|
|
|
|
Post by John Kanters on Feb 26, 2012 0:40:13 GMT -8
Wow a couple of weeks have gone by already, not much more has happened to the car but I have been busy organising my tools so that the serious work can begin so this update is more about that. Bought a cheapo bead roller a while back so I set to work reinforcing the main frame and adding an electric drive to it, did that with a 30:1 worm / roller and a variable speed drill. The drill I have isn't really powerfull enough at ultra low speed so I'm looking around for something with more punch. The concept works extremely well but the drill is the weak part. Also cut down a trolley I had to mount the bead roller and english wheel on, keeps things tidy and stops them walking around the floor. Last thing Saturday I started making the roller profiles to be able to roll the ridges for the new panel above the transmission. Hopefully in the coming weeks I'll be fabricating some panels!   |
|
|
|
Post by John Kanters on Mar 2, 2012 21:53:06 GMT -8
What a great day working on the Ghia! Time had come to start on making the replacement panel for under the rear seat. Last week I made the appropriate shape dies in the lathe for the deep grooves that are in that panel, after running a couple of test pieces I soon realized it distorts the rest of the panel quite badly when bead rolling such a wide deep groove. The solution turned out to be quite easy, by pre stretching the area where the groove goes in the english wheel it raises / stretches the metal thus keeping the sheet more flat when rolling the groove. Unfortunately the throat on my cheapo bead roller isn't deep enough to make the panel in one piece so I decided to make it in 3 pieces, started out with the center panel and marked out the center groove and once this was rolled I pressed the ends with a press tool I made to final shape the ends of the rolled groove. Worked outwards from there and to finish off folded the front and rear lips to end up with the below.    Once that was made I set to work making the new legs to support it, those were easy enough in the press brake. The end pieces were quite challenging also and kinda glad I made the separate as it also allows me to fine tune the total length of the finished panel. Some templates of the wheelhouses helped a lot as the old panel was soo badly rusted that I couldn't copy them. Few trial fits with the cardboard I marked it out on sheetmetal, rolled the groove, bent up the edges and offered it up in the car which looks pretty good.   Last job for the day was to punch the holes of the body bolts to go through and attach on of the side pieces after some careful measuring in the car. I'm super stoked how this came out considering I've never used a bead roller, possibilities seem endless  |
|
|
|
Post by Jürgen Klein on Mar 3, 2012 9:56:52 GMT -8
Great work ! The sheats are looking fine !
I`m a great follower of your resto-story ...
Let us see more !
Jürgen
|
|
|
|
Post by John Kanters on Mar 3, 2012 14:04:33 GMT -8
Thanks Jurgen, if there's particular things you want to se pictures of don't hesitate to ask.
Next on the list will be the big panel over the transmission, I can already see this will be a headache to make and most probably will be made from 2 or 3 sections.
Funny how you so quickly reach the limits of the machines we buy, seems they are never quite big enough..............I'm having a lot of fun learning though.
|
|
|
|
Post by bobnotch on Mar 3, 2012 17:55:18 GMT -8
Looks good John. I look forward to seeing your "above the transmission" piece. Mine was rusted out there pretty good, but I got luck and was able to source a section from Doug.
|
|
|
|
Post by John Kanters on Mar 4, 2012 19:23:08 GMT -8
Well Bob I've been thinking about that panel for most of the weekend  , getting the groove to radius would always be the problem. Having a few hours spare time today I played with some ideas, it just isn't possible in the bead roller................  with the 70 degree downward angle on the sheet it fouls on the bead roller frame well before a 70deg angle. Sooooo after thinking some more the other option would be to run the groove, stop and re start the groove on the other side of the radius (if that makes sense?) But in all honnesty I didn't want to give up on a continuous groove soo easily so in the end I made another press tool and ran a couple of test pieces, works primo!! Where the panel bends back the other way (at the floor pan end) I'll make another press tool the reverse of what I have and that way I should be able to make that whole panel in one piece.   |
|
|
|
Post by John Kanters on Mar 7, 2012 20:15:23 GMT -8
I realise this is a long shot but I'd really like to find a sunroof cut for this car, with the amount of repairs the pillars need it would be easy enough to graft another roof on.
Would love to hear from anyone that knows of something or may have some leads.
|
|
|
|
Post by John Kanters on Mar 8, 2012 18:46:08 GMT -8
The big panel is beginning to take shape but man is it a lot of work! Been trying to do an hour or so after work each day and started out by making a couple of test pieces as shown before which went well so filled with confidence I started marking out the main panel and rolling the beads Where the bead stops and starts it just distorts the panel like crazy but all that went away once I pressed the radiused parts, lucky that the whole panel fits in the press otherwise that would be another thing to figure out.   With one radius done I'll be able to hopefully press the other side tonight, the top part of the panel near the engine bay has these oblong holes for the body bolts to go through which also have a stepped edge as well so again a simple press tool for that looks like it will work going by the test piece I did yesterday  Tomorow I'm hoping to cut the old panel out, clean everything up and get the new panel edged and fitting in there. I'll have to sandblast the whole area before I weld any of the new stuff in though. |
|
|
|
Post by Greg Skinner on Mar 8, 2012 20:34:22 GMT -8
I have a sunroof clip that I might consider parting with--but beyond purchase price, it would cost you a bazillion dollars to ship in from the States. The way your panel beating skills are shaping up, you could probably fabricate one! REALLY nice work, there.
|
|
|
|
Post by John Kanters on Mar 8, 2012 21:31:15 GMT -8
Hi Greg
Thanks for the kind words, shipping to NZ won't be the problem and I'm in absolutely no hurry so at some stage I'll have another car or bus coming over that it can hitch a ride with so I'd be interested to talk to you further about your clip that might be available.
I did think about making one but for that I'd really need an original in front of me to copy and since I don't have that it makes it much more difficult besides then you still need all the electrical parts and cables as well.
|
|
|
|
Post by bobnotch on Mar 9, 2012 8:46:31 GMT -8
I almost did that too, since all 4 of my roof pillars were rusted thru. Greg even offered that section to me, but I was too far along with my pillar repairs to back track. In the end though, I'm glad I just left the roof I have on the car, since it simplified the repair work. Well, that and I want to drive my car this year.  And I'm close to doing that. ;D I've been working on mine off and on for almost 2 years now, and it's almost ready to hit the road. |
|
|
|
Post by Jürgen Klein on Mar 9, 2012 11:20:45 GMT -8
He , Bob , what are 2 years ? Working on a blue/white 34 Ghia can take 23 years - you know it ...!?
Jürgen
Sorry , John , I only have a spare roof without sunroof .
|
|
|
|
Post by John Kanters on Mar 9, 2012 12:25:01 GMT -8
Personaly I would not cut it through the pillars to install the roof, instead I'd drill off the roof skin only and install the new roof that way for a more factory finish.
Cutting the pillars is difficult to measure accurately and much more potential for the window openings to change.
|
|
|
|
Post by John Kanters on Mar 9, 2012 21:26:07 GMT -8
Managed to finish off pressing the other side of the beads on Friday night which helped to straighten out the lower portion of the panel. Made steady progress on the car today chipping away at the trans panel, got the oblong holes pressed first and then started to cut out the old trans panel which seemed to take forever  Maybe I was just too eager to get the new one fitted haha!  With the old one gone and left with a big hole where everything was I cleaned up all the flanges where the new one is going to live. Looking at it further I figured it would be much easier if the rear bulkhead came out too and since it was already unpicked from the lower rear windshield edge and also from the trans panel it just left the sides to drill off so I just did that and removed it. The other bonus is that I can sandblast and prime it before it goes back in. Now for the tricky part, folding the weld edges up on the new panel!  Took some measurements in a few places and made a cardboard template which was transfered and marked out, measured again to double check and started to fold the lip with a hammer & dolly. Dropped the panel in and was surprised how well it fitted, secured it in place with a bunch of screws for now. Finished the day with this...................will take it out again to final trim to size and hopefully sandblast the whole area next weekend  Once everything is sandblasted and epoxied the new stuff can begin to be welded in place for good.  |
|
, getting the groove to radius would always be the problem.
with the 70 degree downward angle on the sheet it fouls on the bead roller frame well before a 70deg angle.
And I'm close to doing that. ;D I've been working on mine off and on for almost 2 years now, and it's almost ready to hit the road.
