1962 Deluxe restoration

[sunroof]

Sorta kinda inching my way along here...

Still modifying the Klokkerholm panel to be correct enough to go into place.

To begin with there was this raised area that didn't match anything on the car

Made some cuts, smashed it flat and welded it back together

Cut the missing doubler for the mounting bolt out of the old panel and spot welded it in place

Cut this big tail section off the back doubler and reshaped the remainder to match what it should look like.

(more or less)

These two are now ready to go back together. This might be a little tricky because they don't fit snug like they should. Evidently when they were made they fit really poorly so the manufacturer just welded them together as best they could and called it done

Also tonight I fabricated this piece

Cut a hole to match

Fitted it in place

Shot some sparks and, like Klokkerholm did, called it done

One of these days I will have to spend some time grinding. I wonder if I should just hire a monkey from the local high school to do it.

Don
_________________
Better and better mistakes!

[Busstom]

[sunroof]

All together it was about 4 hours to get this piece into shape to weld into the car.

We'll see what tomorrow brings

Don
_________________
Better and better mistakes!

[sunroof]

It brings this:

I really hope I don't have to cut this apart

Next is welding in the heater channel.

Actually next is grinding a ton of primer off the heater channel.

Don
_________________
Better and better mistakes!

[sunroof]

Grinding primer off done hopefully...

It fits, more or less:

prêt à weldment (j'espère)

Don
_________________
Better and better mistakes!

[sunroof]

First test fit of the whole assembly. Couldn't be happier

I have to figure out what to do with this little tag, where does it weld to?

Don
_________________
Better and better mistakes!

[sunroof]

That went well.

Next is to fill this hole:

I made up this piece in the usual way with the masking tape but wasn't happy with the result.

The bottom did not exactly align with the rest of the original panel so I added and inch and trimmed it to fit better and sprayed some primer on it

Stack 'o dimes. That also went well.

Now I have to tackle this bit of nonsense

I made the mistake of only cutting away half of the inner quarter so I cut the rest away as well

This is great news, all the complex curve part is rust free so I don't have to recreate that.

but it does mean that these two will have to be " reunited and it feels so good..."

Waiting now for repair panels to come from Klassicfab. I hope they don't need too much work to fit.

Another giant hole

Victor Frankenstein would be proud.


Don
_________________
Better and better mistakes!

[VW_Jimbo]

Yes! Yes, he would. Especially if you started to stitch weld, instead of plug weld!

Looking great! That ear at the exterior gets welded to the side of the heater channel. Then the quarter panel wraps over and around that, creating 3 layers of steel. Then flame weld the leading edge at the exterior, exposed channel, and file smooth.
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[sunroof]

[sunroof]

Only this much will I replace

I think tomorrow I will throw some sparks

Don
_________________
Better and better mistakes!

[sunroof]

Continuing from yesterday, welded on the "coat tail"

And trimmed the weld strip to fit

Threw a whole lotta sparks

Delightful!

Love that copper primer

And on to this little bit and the inner quarter is done

Don
_________________
Better and better mistakes!

[sunroof]

This is what I'm trying to reproduce

This final piece was:

a) Not tricky at all

b) A little tricky

c) Somewhat tricky

d) Very tricky

e) Impossible

The correct answer is c) Somewhat tricky

Acceptable. Trim a little and punch some holes...

And I am calling the inner quarter done.

Don
_________________
Better and better mistakes!

[Bub]

[VW_Jimbo]

Hey Bub! Let me correct that last sentence for you.

IT ADDS UP FAST!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[sunroof]

Nice to know someone's watching.



Don
_________________
Better and better mistakes!

[sportin-wood]

I watch too, silently, only because I know ZERO about welding and fabricating and really have nothing to add besides encouragement and my admiration for your skills. Love the progress and look forward to the finished product!

(Same goes for VW_Jimbo's thread - dude is amazing with his skills!)
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Paused 66 project bug
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"Relax, all right? My old man is a television repairman. He's got this ultimate set of tools. I can fix it." --- Jeff Spicoli

[toxicavenger70]

That back corner section that the heater channels connects to has multiple layers like you figured out. It was like I was making a lasagna when I replacing the metal on mine, just layer after layer. And like you figured out those Klocker panels are way off and cause a bunch of confusion trying to figure out what it should actually look like.

Great job and thanks for taking on us on this journey with you!

[sunroof]

For the one who is paying attention, I have not posted for a while because this happened:

I decided it would be a good idea to hang the door befor I started welding on the back of the car. It has been 2 weeks of struggling with the car to get the door to close but I think I have it now.

The upper hinge was a mess

So I made a tool and pushed it back as much as I could

I also cut the back end of the heater channel free

And cranked the body into alignment with a come-along

At one point I got a little frustrated

After 2 weeks of fighting with it I finally got the door lined up and opening and closing properly

Which means on to the outer rear quarter

This will have to do I'm afraid

Don
_________________
Better and better mistakes!

[Puppy67]

Awesome work on the car so far, especially getting the door back. I remember the huge feeling of both relief and satisfaction when going from this

and this

to this...

Link

[sunroof]

So here we have a good example of "What the hell were they thinking?"

The hole for the bottom fender bolt is in the wrong place and it's a very funny shape. Perhaps there is enough variability in construction to make it impossible to know where the bolt goes?

Well I know where it goes so I am going to correct that

That should work

These are ready to go into place.

I see some welding in my future

Don
_________________
Better and better mistakes!