Re: BigKev's 1954 Packard Clipper Deluxe Sedan
Posted by BigKev On 2011/10/31 23:22:22
More progress tonight. Instead of cutting out the entire log leg and then trying to seamlessly merge the new skin into the existing good panel in the middle of a flat panel, I decided to only replace the damaged area so the merge panel lower in the panel when it would not be as obvious.
So with that I marked the dogleg far into the good metal above the rotten area. Once that was marked I transferred that to the new skin. Then I cut the new skin to that mark. Then I cut out the old skin with a cutoff wheel. On the side I left about a 1/8"-1/4" edge on the old skin which the new skin will lay over. On the top where the two skins have to merge, I left about 3/8 of an inch. The is to give me an over hang for the new skin to slip under.
With the old panel cut away, I could see the rust and dirt packed behind the panels. The inner panels was completely rotten. This was removed as it is not needed and just leads to dirt getting trapped between double layers and causing the rot in the doglegs to start with. The replacement panel will be fully welded all the way about instead of just two layers spot welded in place. So once completely welded, there will be no where for rust to get behind the panel unlike the original consturction where dirt, dust, and water could easily get up and into the gaps between the spot welds along the exposed edge. With the inner rotten layer cut out, the inside of the rocker was painted with some POR-15 paint and left to dry for a little bit.
I then put a step flange into the new skin along the edge where is merges with the old skin. This was then notched inward a little bit. This allows it to key into and under the old skin. Thereby giving a perfectly flat transition between the two skins. One the skin was in lined to and held with a clamp, I then tack welded the merge seam and then down the outside of the wheel well. I also tack welded the new skin to the existing outer rocker panel. The skin edge near the door needs to be ground down a little more as the skin had a small about over overhang. Then I can weld that side. Once the top every top side is tacked into place, then I will roll the bottom edge around and weld it in. But I ran out of time and energy tonight.
Learning as I go. But not to bad so far for a panel that had a lot of curvature in it.
Attach file:
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So with that I marked the dogleg far into the good metal above the rotten area. Once that was marked I transferred that to the new skin. Then I cut the new skin to that mark. Then I cut out the old skin with a cutoff wheel. On the side I left about a 1/8"-1/4" edge on the old skin which the new skin will lay over. On the top where the two skins have to merge, I left about 3/8 of an inch. The is to give me an over hang for the new skin to slip under.
With the old panel cut away, I could see the rust and dirt packed behind the panels. The inner panels was completely rotten. This was removed as it is not needed and just leads to dirt getting trapped between double layers and causing the rot in the doglegs to start with. The replacement panel will be fully welded all the way about instead of just two layers spot welded in place. So once completely welded, there will be no where for rust to get behind the panel unlike the original consturction where dirt, dust, and water could easily get up and into the gaps between the spot welds along the exposed edge. With the inner rotten layer cut out, the inside of the rocker was painted with some POR-15 paint and left to dry for a little bit.
I then put a step flange into the new skin along the edge where is merges with the old skin. This was then notched inward a little bit. This allows it to key into and under the old skin. Thereby giving a perfectly flat transition between the two skins. One the skin was in lined to and held with a clamp, I then tack welded the merge seam and then down the outside of the wheel well. I also tack welded the new skin to the existing outer rocker panel. The skin edge near the door needs to be ground down a little more as the skin had a small about over overhang. Then I can weld that side. Once the top every top side is tacked into place, then I will roll the bottom edge around and weld it in. But I ran out of time and energy tonight.
Learning as I go. But not to bad so far for a panel that had a lot of curvature in it.
Attach file:
(56.77 KB)
(48.54 KB)
(68.75 KB)
(70.76 KB)
(57.53 KB)
(92.57 KB)
(60.90 KB)
(47.62 KB)
(44.56 KB)
(38.12 KB)
(48.65 KB)
(54.43 KB)
(73.57 KB)
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