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  #51  
Old 01-04-2018, 04:17 AM
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Gojeep Gojeep is offline
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Thank you Steve for showing how you went about it. I always workout how I would do it and then see if it matches up. There are always more than one way so good to see the different ways to learn more.
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  #52  
Old 01-07-2018, 12:35 PM
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The bottom part of the B pillar had completely rusted away.

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The Drivers side was intact but most of it is covered by the fiberglass door jamb and quarter panel. this looks rough but should be salvageable after sand blasting. that was left for the Corvette shop.

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the silver panel shown here is a repro for part of the rain gutter, the owner supplied them and the full repro gutter that starts at the base of the windshield and fits along the front, top and back of the door opening.

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the gold part here is a repro door jamb structure that was only mounted with a couple temporary screws to a sill panel that had been replaced also. I did not know how accurate the sill was located, and the jamb support was floppy at the top. Sooooo not a lot of good information.

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made tag board patters of what was visible on the drivers side.

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cut out blanks. due to the crazy shapes and a need to do a lot of trial and error fit up checks, I chose to cut small parts and weld at the edges. If more information was available some of it could have been made of larger parts with bent corners.

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Small screws work good to make sure you get repeatable fit up. I get them at Menards. Hex head, #6 & #8 1/2 & 3/4 length, self drill and tap.

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Steve
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  #53  
Old 01-07-2018, 01:20 PM
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Steve Hamilton Steve Hamilton is offline
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Must have had these parts in and out a hundred times. every time you weld an area, the panel changes shape and needs to be planished, twisted stretched etc.

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What a convoluted shape! one small step at a time and keep checking the fit up.

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An offset was needed for the fiberglass, so with it clamped to a heavy bench, was able to use a square block of steel and hammer to form it.

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Nothing was stable, shown here, the lower windshield structure, A pillar, And door hinge support have all been replaced and only held in place with screws. I pulled the top of the cowl forward to support the door correctly in the opening.

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sorry for the dark pictures, tried to show that the gaps between the door and the new parts were good.

Steve
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  #54  
Old 01-07-2018, 04:14 PM
Turbo57 Turbo57 is offline
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Ty for sharing , i learn so much how other solve problems
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  #55  
Old 05-08-2018, 09:41 PM
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Oh where does the time go!
guess I got side tracked. I was reminded by someone up at Dan's that I had not finished this thread. Sorry, well here are the last pictures.
Many small parts were required to make the box part at the front of the Quarter panel. The areas that were to be welded as an enclosure received a coat of self etch primer to help slow down the corrosion in the future.

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Mike Rouse had asked early on how it would be welded?

The answer is most of it was TIG to assemble the panel sections, then the lap and flange joints were spot welded the same as the factory did.

The customer was thrilled to find someone that could make this, so the restoration could continue.

I had estimated (wild ass guess) that this would take 40 hours but explained to the customer that it could be much more. we had a conversation when I reached 30 hours and could see that the estimate wasn't even close, he agreed to continue with the high quality for what ever it took to complete. the project took a little over 80 hours and number of hours thinking & head scratching!



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Last edited by Steve Hamilton; 05-09-2018 at 09:06 AM. Reason: add last paragraph
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  #56  
Old 05-09-2018, 05:49 AM
RockHillWill RockHillWill is offline
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Very clever work my friend!
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  #57  
Old 05-09-2018, 06:00 AM
cliffrod cliffrod is offline
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Looks good, Steve.
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  #58  
Old 05-09-2018, 09:08 AM
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edited my last post, added last paragraph

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  #59  
Old 05-09-2018, 09:20 AM
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Thanks for showing the process you went through and also for editing and adding the info from estimate “W.A.G” to actual labor hours involved. It’s so difficult to quote 100% custom work with so many variables involved. I also find myself forgiving some of my “head scratching” and thinking hours as I find it difficult to charge a customer if I don’t exactly know how to do something (can’t charge 100% for learning something myself) Do you find yourself with the same mindset also?

Lastly, your finished pieces look like a mangled pile of scrap metal that someone ran over.....I mean that as a compliment!! It’s such an odd complex mix of curves and shapes to recreate and you pulled it off very nicely!
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  #60  
Old 05-09-2018, 09:24 AM
Mike Motage Mike Motage is offline
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Amazing work on a complex piece!
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