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  #11  
Old 01-03-2018, 09:12 AM
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pplace pplace is offline
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Quote:
Originally Posted by custommetal View Post
Super metalworking skills and planning. Never gave any thought to checking the weatherstrip fit when I chopped the top on my 56 chevy pu. Had to add some flat foam tape to the inside for a better seal. Luckily it was grey on grey. Thanx for taking the time to photograph and post.
George
Thank you. Still it seems as much as a person plans and thinks something out, something else will pop up down the road that you forgot!ha. As for the weatherstripping it’s nice to even have a set of “building” weatherstrip just for fitting purposes during construction.
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  #12  
Old 01-03-2018, 06:17 PM
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The next task on the project was shaping some new front fenders. As mentioned / shown slightly in a previous post someone had attempted to modify the fenders and wheel openings. I took this "problem" and decided to just correct the issues as well as change the wheel opening to a different shape / diameter to match the wheels better.

I created a fairly simple buck to help create the new opening that we wanted, and to help start the shape of the "S" profile created by the wheel opening / "flare" This flare actually tapers from wider in the front to narrower in the rear to account for the narrowing of the front fenders from the door to the headlights (the flare stays parallel to the wheel & tire basically"

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I shaped each fender out of four main pieces. Here I've got each panel shaped pretty close and am doing some final fitting & aligning.

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I took this opportunity to remove the bolt on front end panel seam and incorporated it into the fender.

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Once the panels were all fitting properly I rolled the wheel lip and tacked all four panels together.

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The picture from the rear view shows how I now attached the fender panel to the previously fabricated fender jamb.

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After the main portion of the fender and wheel opening / flare were shaped I focused on shaping up the bottoms of the openings in order to blend and finish them off into the fender.

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Close up view showing all the panel alignment after tacking them together

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All sections of the fender have been fully welded and in the picture have about 85-90% of the welds planished and finished.

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All sections of the fender have been fully welded and in the picture have about 85-90% of the welds planished and finished.

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A close up showing the soft roll / radius on the wheel opening.

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Duplicated all this work on the passenger side as well.

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  #13  
Old 01-03-2018, 08:03 PM
NEB Alan NEB Alan is offline
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Very impressive. You have a truck that people will not see the changes you have made since they appear to be "factory".
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  #14  
Old 01-03-2018, 08:41 PM
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Now the time came for one of the tougher portions of the project.....the doors! For numerous reasons and after much contemplation I decided it was best to build new door basically from scratch (maybe used 5% or original door in parts)

The reasons for this choice:

~The door shells were rusted and patched
~The door had been cut up quite a bit for the previous suicide hinge install
~I had to lengthen the doors on the bottom to account for not having the running boards anymore.
~The top chop hadn't done much good to the inner and outer door tops.
~The exterior skins weren't terrible, but did have some patches, shaved handles, and damage.

Besides the lower interior window opening / belt line. These are only remaining items I salvaged from the original door.

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I thought I had more "in progress" pictures of the door shells, but this is all I see on my computer.

Here I've already fabricated the front, bottom and rear portion of the door shell and have the hinges installed and tacked checking for proper door operations.

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View with the door open (top window opening skin is temporarily in place)

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View of the interior side of the door shell.

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Once I had the door shell roughed out I moved onto forming a "C" channel for the window. I created a buck (Just some MDF of the correct thickness) and made a matching set of window channels. Driver side and passenger side)

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Here I've installed the "C" channel and have mounted the electric window setup as well as the door latch and solenoid "popper"

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A view of the passenger side at the same point, however here the mock up window is in the up position.

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I could then start shaping the upper door shell around the window channel.

I also fit a flat inner door panel for now....waiting to trim any openings or ribs, etc. until I knew exactly where I would need access eventually

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The exterior door top pieces were reshaped, and added to where needed. I did add new material around the top perimeter and tipped it over 90 deg. so I could hem it to the door shell when ready.

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In the process of folding the hem over onto the door shell flange

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Finished hem

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Door top basically finished inside and out.

NOTE: I do not have the upper cab door jamb installed in this picture, thus the gaps around the door top (that's a story for another post later)

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During the process I had my mock up window (correct thickness) so I could fit all the window run rubber and also made and fit the inner and outer door sweep "fuzz" so I could shape and locate the inner and outer door skins properly.

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  #15  
Old 01-03-2018, 08:56 PM
Oldnek Oldnek is offline
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Very nice work you are doing, Dane, your attention to detail is outstanding.
Pretty awesome.
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  #16  
Old 01-03-2018, 10:02 PM
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pplace pplace is offline
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Default Start of roof repair

Quote:
Originally Posted by Oldnek View Post
Very nice work you are doing, Dane, your attention to detail is outstanding.
Pretty awesome.
Thank you, I appreciate the comments.

Next up is the roof! The roof was pretty cut and spliced up from the previous chop attempt. The transitions from the roof to the edges front and back as well as into the door tops was "off" very flat in spots with no real flow.

This post will show what I had to start with and also a couple pictures of some of the pieces I shaped around the perimeter of the roof (I did save the center of the roof) I'll do another post with the actual fitting and welding of these pieces into the roof.

This "before" picture shows the numerous seams, relief cuts and welds in the roof. I can see three seams across the roof from door to door just in the front half of the alone. Several relief cuts at the top of the "A" pillar as well

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View from the other side. Pretty much the same story, lots of seams and mis-aligned welds.

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Even in the early stage of rough shaping the new front section of the roof you can see the "lows" from the previous welds going across the roof.

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Here I've started to shape up new panels around the roof. Some are final shaped more than others in this picture. In this pic there is the front half of the roof panel, the "A"-pillar panel, a panel above the door top and the rear corner of the roof.

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A view from the rear showing some of the panels taking their shape. This also shows I did a panel above the rear window (I don't recall why I made that particular piece in two halves? Split at the centerline of the cab?) I may have done it so I would only have needed to remove half the original roof piece to help maintain some structure / shape? Either way, I know it all worked out in the end!ha

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Another pic from the rear, just a different angle. This shows the rear center portion of the roof that I was able to save.

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  #17  
Old 01-04-2018, 02:49 AM
steve.murphy steve.murphy is offline
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Nice work this is an epic thread. The untouched sheetmetal amount must be very small!
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  #18  
Old 01-04-2018, 03:31 AM
Gojeep Gojeep is offline
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Excellent work. What are you using to shape most of your panels with?
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  #19  
Old 01-04-2018, 04:29 AM
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Kerry Pinkerton Kerry Pinkerton is offline
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Very impressive work Dane. You sir are no hack!
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  #20  
Old 01-04-2018, 07:48 AM
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pplace pplace is offline
MetalShaper of the Month March 2018
 
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Quote:
Originally Posted by steve.murphy
Nice work this is an epic thread. The untouched sheetmetal amount must be very small!
Thank you very much! I'm glad I'm able to share this project with others. There was very little original metal used.....just used it as a rough "guideline" and base to start either repairing or modifying from.


Quote:
Originally Posted by Gojeep View Post
Excellent work. What are you using to shape most of your panels with?
Again thank you! Nothing too fancy here.

Homemade english wheel
Shrinker & Stretcher
Deep throat Shrinker / Stretcher
Bead roller
Metal brake
Sandbag
Hammer and dollies
Time!!

Quote:
Originally Posted by Kerry Pinkerton
Very impressive work Dane. You sir are no hack!
Thank you very much! That really means a lot. I'm 100% self taught through trial and error, research, taking ideas and techniques from what others do online, etc. I'm fairly "youngish" currently at 36 (this project was from about 2 years ago however) but have gained a large interest in shaping and forming metal over the years. When I shape projects I try to plan out according to my skill set and see how far I can get.
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