Packard Forum Index » Project Blogs

Inner A-pillar welded, smoothed up, and mopped with epoxy.

<a href="http://s557.photobucket.com/user/theastronaut/media/Random/8C56B8C6-92CA-4C9C-9C14-C865FFE5106E.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/8C56B8C6-92CA-4C9C-9C14-C865FFE5106E.jpg" border="0" alt=" photo 8C56B8C6-92CA-4C9C-9C14-C865FFE5106E.jpg"/></a>


Used tape to locate the edge of the outer skin, this will help with trimming the outer layer to size without having too big of a gap.

<a href="http://s557.photobucket.com/user/theastronaut/media/Random/D5D6C7B9-43C6-4F29-A5DC-104AF8990249.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/D5D6C7B9-43C6-4F29-A5DC-104AF8990249.jpg" border="0" alt=" photo D5D6C7B9-43C6-4F29-A5DC-104AF8990249.jpg"/></a>


Outer skin stuck in place, another layer of tape placed over the first piece. The bottom edge of the tape will be the cut line.


<a href="http://s557.photobucket.com/user/theastronaut/media/Random/60C3034D-4D3C-4102-B2C9-D00C851FD398.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/60C3034D-4D3C-4102-B2C9-D00C851FD398.jpg" border="0" alt=" photo 60C3034D-4D3C-4102-B2C9-D00C851FD398.jpg"/></a>


Outer skin welded in place, welds smoothed.

<a href="http://s557.photobucket.com/user/theastronaut/media/Random/947D4B3A-03F0-4085-ADA2-0D0A39486439.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/947D4B3A-03F0-4085-ADA2-0D0A39486439.jpg" border="0" alt=" photo 947D4B3A-03F0-4085-ADA2-0D0A39486439.jpg"/></a>

Inner A-pillar brace welded in.

<a href="http://s557.photobucket.com/user/theastronaut/media/Random/56D2D9BB-6C1A-4092-B2E0-953315F7BDA7.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/56D2D9BB-6C1A-4092-B2E0-953315F7BDA7.jpg" border="0" alt=" photo 56D2D9BB-6C1A-4092-B2E0-953315F7BDA7.jpg"/></a>


Inner cavity mopped with epoxy after welding.

<a href="http://s557.photobucket.com/user/theastronaut/media/Random/C822D954-8D08-43DB-A92C-11FA294A44B8.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/C822D954-8D08-43DB-A92C-11FA294A44B8.jpg" border="0" alt=" photo C822D954-8D08-43DB-A92C-11FA294A44B8.jpg"/></a>


And a "work in progress" shot. Currently working on getting the outer rocker ready for welding.

<a href="http://s557.photobucket.com/user/theastronaut/media/Random/70185D19-1E62-4AED-9315-EECDA01DD117.jpg.html" target="_blank"><img src="http://i557.photobucket.com/albums/ss14/theastronaut/Random/70185D19-1E62-4AED-9315-EECDA01DD117.jpg" border="0" alt=" photo 70185D19-1E62-4AED-9315-EECDA01DD117.jpg"/></a>

I have the rocker, inner and outer B-pillar pieces, and the lower cowl panel welded in.

Next step is to get the lower quarter panel fitted and welded in, then start leading the seams. To position the quarter I set the door in place to match quarter bottom to the door bottom and make sure the bottom edge carried the same line. The edge of the door (black) was blending into the black frame so I added blue tape to the edges of both panels to help visualize the line better.


<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12745924_912373335548152_1900076111292534443_n_zpspfktkmnj.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12745924_912373335548152_1900076111292534443_n_zpspfktkmnj.jpg" border="0" alt=" photo 12745924_912373335548152_1900076111292534443_n_zpspfktkmnj.jpg"/></a>


Fitting and finishing the cowl panel:

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12742755_912373292214823_3924612011526589471_n_zpsfaceeely.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12742755_912373292214823_3924612011526589471_n_zpsfaceeely.jpg" border="0" alt=" photo 12742755_912373292214823_3924612011526589471_n_zpsfaceeely.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12524257_912373398881479_5915024655328320204_n_zps1duocnqy.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12524257_912373398881479_5915024655328320204_n_zps1duocnqy.jpg" border="0" alt=" photo 12524257_912373398881479_5915024655328320204_n_zps1duocnqy.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/717_912373418881477_4314247061187341006_n_zps22jdjjwz.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/717_912373418881477_4314247061187341006_n_zps22jdjjwz.jpg" border="0" alt=" photo 717_912373418881477_4314247061187341006_n_zps22jdjjwz.jpg"/></a>

Rocker and B-pillar brace welded in.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/10154392_912373252214827_5286836193760095967_n_zpsbxdudagw.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/10154392_912373252214827_5286836193760095967_n_zpsbxdudagw.jpg" border="0" alt=" photo 10154392_912373252214827_5286836193760095967_n_zpsbxdudagw.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12743886_912373368881482_4055861111861723166_n_zpsdjrsw5q5.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12743886_912373368881482_4055861111861723166_n_zpsdjrsw5q5.jpg" border="0" alt=" photo 12743886_912373368881482_4055861111861723166_n_zpsdjrsw5q5.jpg"/></a>

Since the door was out I took a few pictures. You might want to make sure there are no children around when you scroll down, it's pretty scary...

They're patched up so bad that they won't fully fit in the door jamb without hitting the rockers. Now it makes sense that the old rockers were bashed in and bondo'd as bad as they were. Like the rest of the body, the door is fixable with enough work but it would make more sense to just start with a better door if we can find one.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12321644_912373102214842_500246369132955378_n_zpsw4gy7epg.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12321644_912373102214842_500246369132955378_n_zpsw4gy7epg.jpg" border="0" alt=" photo 12321644_912373102214842_500246369132955378_n_zpsw4gy7epg.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12728790_912373075548178_1468280605993993312_n_zpsoodlb7o3.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12728790_912373075548178_1468280605993993312_n_zpsoodlb7o3.jpg" border="0" alt=" photo 12728790_912373075548178_1468280605993993312_n_zpsoodlb7o3.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/10156110_912373018881517_5939869064491839959_n_zps7ahsju3e.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/10156110_912373018881517_5939869064491839959_n_zps7ahsju3e.jpg" border="0" alt=" photo 10156110_912373018881517_5939869064491839959_n_zps7ahsju3e.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/1375792_912372968881522_6631542321203551584_n_zpspedrhsnp.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/1375792_912372968881522_6631542321203551584_n_zpspedrhsnp.jpg" border="0" alt=" photo 1375792_912372968881522_6631542321203551584_n_zpspedrhsnp.jpg"/></a>

And that's just the bottom... the middle of the inner skin somehow rotted out. Very unusual place to have rust holes.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12728981_912373042214848_7354105814873345901_n_zps3qwcbxwl.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12728981_912373042214848_7354105814873345901_n_zps3qwcbxwl.jpg" border="0" alt=" photo 12728981_912373042214848_7354105814873345901_n_zps3qwcbxwl.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12733451_912372992214853_851908402481782383_n_zpshwukhn1s.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12733451_912372992214853_851908402481782383_n_zpshwukhn1s.jpg" border="0" alt=" photo 12733451_912372992214853_851908402481782383_n_zpshwukhn1s.jpg"/></a>


If that wasn't bad enough, most of the inner front edge is rusted through.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12670913_912373148881504_5282966408542756079_n_zpsyjow4mar.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/Facebook/1940%20Packard%20120%20Convertible%20Restoration/12670913_912373148881504_5282966408542756079_n_zpsyjow4mar.jpg" border="0" alt=" photo 12670913_912373148881504_5282966408542756079_n_zpsyjow4mar.jpg"/></a>

I'm back in from the "Redneck Roundup" metalshaping get-together in Rock Hill. This was a three day gathering of 40-45 people from all over the United States, plus Per "MetalmanSweden" from Sweden, and another talented metalshaper, Ben Van Berlo from Holland. I made new friends and learned a lot from watching the other guys work on their projects and the various presentations throughout the weekend. Great bunch of people and I hope to attend again next year.


One of the things I learned more about was the "flexible shape pattern". I've seen pictures of them posted on the allmetalshaping.com forums but didn't know anything about them. One of the presentations on Friday included a brief discussion on them so I thought that the passenger side fenderwell lip would be a good place to try one out.


The concept is to use reinforced shipping tape to make a non-deforming yet flexible pattern that shows how much shape a panel has so you can accurately determine how much shrinking or streching the panel needs. It also helps determine if an area of a panel has bends only- no stretching/shrinking needed to arrive at that particular shape.
I used a layer of blue painters tape as the first layer, being careful not to overlap anywhere. Then I used a single layer of reinforced tape on the spots I thought would need to be stretched, and a double layer (at opposing angles) on the area that I though was only bent- the inner flange. Once it's pulled off the panel (the painters tape makes it easy to remove) you use baby powder to kill the adhesive so it can be handled without it sticking to everything.



I didn't get a picture of it before I had removed it and used baby powder on it so I taped it back in place for a quick pic.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12814570_10156516965470468_1094212172105999521_n_zps7mcc3uwk.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12814570_10156516965470468_1094212172105999521_n_zps7mcc3uwk.jpg" border="0" alt=" photo 12814570_10156516965470468_1094212172105999521_n_zps7mcc3uwk.jpg"/></a>



It doesn't look like much pulled off until you weigh down the spots that will lay completely flat, in this case the inner edge. If it will easily lay down with no wrinkels or bucking you know that that area only needs bending to arrive at its final form.



<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12802734_10156516965500468_592390780678100535_n_zpsreouhk08.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12802734_10156516965500468_592390780678100535_n_zpsreouhk08.jpg" border="0" alt=" photo 12802734_10156516965500468_592390780678100535_n_zpsreouhk08.jpg"/></a>


The ruffles along the outer edge won't lay flat. You can see that there is "more" tape for that section than a straight/flat piece so the new metal needs to be stretched in that area.



<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12049493_10156516965580468_3132114364807486958_n_zpszc7ap56k.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12049493_10156516965580468_3132114364807486958_n_zpszc7ap56k.jpg" border="0" alt=" photo 12049493_10156516965580468_3132114364807486958_n_zpszc7ap56k.jpg"/></a>

I cut a blank out, using the flat section of the tape pattern to mark out the inner flange's curve. I probably would have made this in a straight section and used the brake to make the first bend, then stretched and shrunk each side to curve it. With the shape pattern, I already had the correct curve of the flange so I could go ahead and cut it to shape. Once the piece was cut out, I set up the bead roller with mis-matched dies to make a makeshift tipping die to get the curved bend started.


Initial bend and stretching.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12814741_10156516965615468_8212655136547807174_n_zpsyoukskcy.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12814741_10156516965615468_8212655136547807174_n_zpsyoukskcy.jpg" border="0" alt=" photo 12814741_10156516965615468_8212655136547807174_n_zpsyoukskcy.jpg"/></a>



I had some leftover 1/8" plate in the scrap pile that had the same radius as the fender opening. I smoothed the edge and bent it to the same shape as the opening so I could use it as a dolly to form the edge over. This supported the edge, and a piece of tubing hammered beside it made the flared edge.


<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12802928_10156516965660468_494668978378638642_n_zpsulnmhafd.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12802928_10156516965660468_494668978378638642_n_zpsulnmhafd.jpg" border="0" alt=" photo 12802928_10156516965660468_494668978378638642_n_zpsulnmhafd.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12814364_10156516965720468_437388387050408498_n_zpsikvfkl4y.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12814364_10156516965720468_437388387050408498_n_zpsikvfkl4y.jpg" border="0" alt=" photo 12814364_10156516965720468_437388387050408498_n_zpsikvfkl4y.jpg"/></a>

It's roughed in, still needs some fine tuning to match the shape of the opening, and to match the proper gradual increase in flare from top to bottom.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12809745_10156516965880468_1462577022581838959_n_zps90vpzqzj.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12809745_10156516965880468_1462577022581838959_n_zps90vpzqzj.jpg" border="0" alt=" photo 12809745_10156516965880468_1462577022581838959_n_zps90vpzqzj.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12801502_10156516976600468_8240220586545727265_n_zpsfqb3f3ud.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12801502_10156516976600468_8240220586545727265_n_zpsfqb3f3ud.jpg" border="0" alt=" photo 12801502_10156516976600468_8240220586545727265_n_zpsfqb3f3ud.jpg"/></a>

To finish up the quarter panel edge I made a set of templates off the driver side to match up the shape.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12063339_10156536436295468_4087790202609851_n_zpsqexr8rvg.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12063339_10156536436295468_4087790202609851_n_zpsqexr8rvg.jpg" border="0" alt=" photo 12063339_10156536436295468_4087790202609851_n_zpsqexr8rvg.jpg"/></a>



Before and after fine tuning the shape. The templates were spaced every two inches.

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12809542_10156536436315468_1888500225469948002_n_zpscxvdzdej.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12809542_10156536436315468_1888500225469948002_n_zpscxvdzdej.jpg" border="0" alt=" photo 12809542_10156536436315468_1888500225469948002_n_zpscxvdzdej.jpg"/></a>

<a href="http://s1315.photobucket.com/user/andersonautoglass/media/12794353_10156536436375468_5043309231094412637_n_zps6c30i39e.jpg.html" target="_blank"><img src="http://i1315.photobucket.com/albums/t599/andersonautoglass/12794353_10156536436375468_5043309231094412637_n_zps6c30i39e.jpg" border="0" alt=" photo 12794353_10156536436375468_5043309231094412637_n_zps6c30i39e.jpg"/></a>