Re: BigKev's 1954 Packard Clipper Deluxe Sedan
Posted by BigKev On 2011/10/27 22:20:56
On to the next big project...Dogleg replacement.
My 'legs are really bad towards the bottom and the rust is pushing the outer skin out away from the inner panel. They look like they had been patched in the past using fiberglass and bondo.
I bought some poster board at the local dollar store. This is the same thin card board sheet that my kids use for school projects. This was taped over the dog leg area, the I used a razor blade to cut out the pattern.
Once the pattern was cut out, and I then laid it over some 18ga cold rolled steel. The nice thing about poster board is that it is flexible to take most shapes, and is stiff enough to lay firmly again the metal go it it can nicely traced with a sharpie.
Even though the pattern was made off of the passenger side dogleg, the pattern works for either side. So I traced the pattern twice to make 2 dog legs, one for each side.
Then I used a pair of air-shears to cut out the metal. I think that these cheapie HF shears are not rated for 18ga cold rolled. The shears are already dull. But eventually I powered through and got them cut out.
Then I used the only metal bender I had (my knee) to bend the various curves into the new dog leg skin to shape it to match on the contours of the existing dogleg. With that, I called it a night. I still do some more fine shaping, and then also bend down the bottom lip. I also need to the same for the drivers side one. Then I will be ready to cut out the old doglegs and attempt to get the new ones welded in. This same general technique will be used to also repair the rear corners of the wheel well.
Attach file:
(45.93 KB)
(31.76 KB)
(33.43 KB)
(33.23 KB)
(63.14 KB)
(53.97 KB)
(42.08 KB)
(45.68 KB)
(40.46 KB)
My 'legs are really bad towards the bottom and the rust is pushing the outer skin out away from the inner panel. They look like they had been patched in the past using fiberglass and bondo.
I bought some poster board at the local dollar store. This is the same thin card board sheet that my kids use for school projects. This was taped over the dog leg area, the I used a razor blade to cut out the pattern.
Once the pattern was cut out, and I then laid it over some 18ga cold rolled steel. The nice thing about poster board is that it is flexible to take most shapes, and is stiff enough to lay firmly again the metal go it it can nicely traced with a sharpie.
Even though the pattern was made off of the passenger side dogleg, the pattern works for either side. So I traced the pattern twice to make 2 dog legs, one for each side.
Then I used a pair of air-shears to cut out the metal. I think that these cheapie HF shears are not rated for 18ga cold rolled. The shears are already dull. But eventually I powered through and got them cut out.
Then I used the only metal bender I had (my knee) to bend the various curves into the new dog leg skin to shape it to match on the contours of the existing dogleg. With that, I called it a night. I still do some more fine shaping, and then also bend down the bottom lip. I also need to the same for the drivers side one. Then I will be ready to cut out the old doglegs and attempt to get the new ones welded in. This same general technique will be used to also repair the rear corners of the wheel well.
Attach file:
(45.93 KB)
(31.76 KB)
(33.43 KB)
(33.23 KB)
(63.14 KB)
(53.97 KB)
(42.08 KB)
(45.68 KB)
(40.46 KB)
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