Amphicar "The only car with the right to rust" Expert level rust repair

[Guest Davethewave]

Not in the mood today for big challenges. So I think I will do a large hole in hull/rocker area.

[Guest Davethewave]

Yesterday spent filling a lot of little holes. Than got started on the hull/rocker. Today is my birthday and will be taking the day off. So will be "playing" on the fiberglass body of my ultra rare HMV Freeway. This one is the factory prototype.:cool:

[Woodfiddler]

Happy Birthday Dave. I hope you have a great day. Tell us more about your HMV Freeway please. I have never seen or heard of the machine. Thanks.

Chuck

[Guest Davethewave]

Today was fix the big hole in the hull day. One easy one and one took a bit of hammer and bag time. I should be focusing on finishing front but.... I was so tired at seeing a hundred little holes every day. Last pic is the "porpoise " When the car is fully upside down it looks like a porpoise to me. With compound curves it is a challenge area. It was funny as my helper would watch. I get in a groove and as it takes shape nothing makes sense till the end. Twisted dented chunk, than some smoothing, trimming and ......a magic welding wand.

[Landman]

Well, it does say in the title; Exprt Level Rust Repair. Right on Buddy! It's taking shape. Like Mr. Bernie says, "Keep on keepin' on." I hope this isn't copyrighted.

[Guest Davethewave]

I only put "expert" in the heading to push myself. I have met experts and they are a joy to learn from. So I am still an apprentice. There are (for me) psychological barriers. I start with a basic plan but do not know what is going to happen till I start the project. Some areas I know are going to be hard. So I start, rough in the area and walk away. I find mistakes do not look like mistakes up close. Its when you get twenty feet away or try to install a part is when you find your error.

Today ended up being a really good day. I have put off the back end as long as I could. The trays are connected to hull. Hull is connected to frame. Filled some large and small holes. Have more "tweaking" but the rear aluminum strips are fitting very well. This was a GIANT hurdle. I still have plenty to do but the engineering (head ache) portion is done.

Also got a patch and some finish welding done on front fender.

In such a good mood had an idea to cut up some MGB fenders for my Amphicar from Hell project!!

[Guest Davethewave]

I guess I was trying to keep up with "Landman". I was happily building the front when the cut off wheel bit me. When I was a kid stitches were a few dollars each. Last time the ten stitches cost about 1200 dollars! Ouch! So paper towels and green masking tape make do.

Not finished but the entire front is hole free!!! The back is 90% hole free! Soon this car will be ready for restoration!

[Landman]

If your 10 stitches cost $1200, then I better not repeat what I did in the US. My bill would likely be $25,000.

[Guest Davethewave]

More more more. Little spots missed or just need more more more. I jumped the gun a little but needed to get epoxy on a lot of bare metal that was finished being welded and ground on. The front wheel houses are Officially welded. Which means the front end is close to completion. A thin coat of short strand fiberglass over any weld seams ( factory used lead). Once the epoxy has cured small imperfections can be filled and sanded.

[Guest Davethewave]

Can it be?!! The bottom of the hull is finished being welded?! Almost.....:cool:

[Guest Davethewave]

Happy Hullidays. Decisions decisions. This hull was so beat. Really have to decide what is important. If money was no object than entire floor, front and back of hull would have been replaced. But than ......... But it is necessary to stay within a reasonable budget. So now the bottom is water tight. The painter can smooth imperfections if the owner wants. I usually smooth dents that can not be pulled or pounded. Some filler primer and than another couple coats of epoxy. From where this project started, I feel pretty good about it. I find I stress on things that really do not matter. Not every car is to be a show car. This one will enjoy being used, scratched and dented.

[Richard1]

I have been impressed by my body guy, but you are really the master.

[Guest Davethewave]

I had to get car off rotisserie. I needed access where it bolted to. Plus I just needed new scenery. Till you start fitting parts you never really know the whole story. I was happy to see engine cover I replaced frame on fit nicely. Then I pulled out the doors. Another major project. Doors are always last. From the factory cars were built on carts and every one is welded or assembled differently. So doors do not always fit right. Now after severe rust and accidents the doors have to be built while on the car. But not today!

HEY Richard, I am ready to work on Mini in Bolivia !!! Hola amigo, quiero cerveza fria por favor.:cool:

Edited January 10, 2013 by Davethewave (see edit history)

[Guest Davethewave]

Finally getting back to the soon to be rust free Amphi. Was in the mood to tackle a door and a rusty spot near windshield. Doors are a multi step program. Lots of time trial fitting. Doors are the hardest part to build properly. Easy to take 20 hours to get tacked up.

Edited February 28, 2013 by Davethewave
spelling (see edit history)

[Guest Davethewave]

This pic is of a so called restored car that was brought over to my shop. Some days I think I worry too much and then stuff like this shows up. They glued on a patch on outside then just screwed a piece of wood over the giant rust hole!!!!! This is structural too. They just do not realize the forces of being in water. I do appreciate the hacks because they keep me busy!!

[Guest Davethewave]

Finally tacked on rear patch panel. Door looks nice but not even close. Still much progress today.

[Guest Davethewave]

This is one reason these cars need to be restored properly. Its called a water wheelie. Perfected by Billy Syxx of East Coast Amphicar. This is a pic of Amphipoda hitting water . We will be doing things like this March 23rd 2013 in Mt. Dora Florida. Noon at Gilbert Park. Stop and say hello. Find me in my metallic blue Amphi and I will try to get you a ride. Later Gator Wave.:cool:

[Luv2Wrench]

Great progress, I love this thread!

[Guest Davethewave]

Thank You. Today was take door apart and adjust. Then decided to start fitment of other door, then worked on rocker. Screwed the panels on just to see. I totally under estimated this and really looking forward to moving onto next project. Still the smile that crosses my face as I look at this. Knowing that some fillers, some sanding and some paint and its salty rusty history will be erased.

[Guest Davethewave]

Today was finish fitting and weld quarters on. Soooooo many steps to get to this point.

[hursst]

Love the post. Keep up the great work!

[unimogjohn]

Really like everything you are doing. Cannot wait until the "launch". Keep up the great work!

[Guest Davethewave]

Door day. Still need to make interior corners. But majority is tacked in. Door fits properly.

[Guest Davethewave]

Daze of welding. Ugh... I like my edges nice and smooth. Less likely to have leaks. I am happy with the results. Funny almost no one will ever notice. But when inspecting a car for someone its the first thing I inspect. Could it be...one or two days left on main shell!!??

Dare I say ...down to the last 40 or so hours??!!

[Guest Davethewave]

Today was tunnel day. The tunnel is where the rubber boot attaches. The boot then attaches to the trans. If in poor condition car can sink. These get hurt when drive shafts explode because previous owner did not grease. Then some small patches on convertible top area. Hopefully tomorrow will be build the other door day.

[Guest Davethewave]

Drivers door daze. I did not like first skin. So made up another. Much done but still have inner corners to make. My shop has been sold and its time to get this done. Due to time some areas that are not seen and pose no problems will stay as is. I hope for some warm weather to finish cleaning and getting a coat of epoxy on. Putting this project out in the open helps me do a better job. I appreciate the nice responses.

[Guest Davethewave]

I so under estimated the time to get to here. The Bible tells us if you make a promise, to keep it even if it breaks you. Well I am not broken!! I look back and it amazes me that this is now going to be a very nice car. There really is a joy about being able to build/restore/repair something that will bring a lot of smiles to others.

[Luv2Wrench]

You've got some smiles here! :)

[Guest Davethewave]

I estimated at 200 hours to get here. OOps.........My job was to strip and do metal work. Every bolt was a fight. Every odd area had a hole. I stopped keeping track after 300 hours. Still plenty to do and I can only hope the owner can appreciate the effort. It is really difficult working for someone long distance, not to mention the language barrier. No matter what the trucker called to pick up today.

Hope to meet some of you at my new shop near Mt. Dora Florida. Later Gator Wave-chomp chomp!!!

[Luv2Wrench]

That wasn't a restoration as much as it was a resurrection! Incredible job.

[Guest Davethewave]

BYE BYE !! I sprayed some yellow for safety. I purposely put expert in heading to push and hopefully improve me. I guess I needed to add a little more stress to the equation. I have started a new Amphi project. All I could was smile seeing so much metal to start with. LOL

Thank You for all of the moral support. It really does help in the difficult times. I think I better send a check to AACA. Later Gator Wave aka Dave the Wave.

[Guest Henry White]

I saw an Amphicar on a trailer here about a week ago. I could tell it had just been painted light blue and there was no door (Hatch? IDK) handles on it. Looks as if it is being restored. A local shop had it on his trailer.

[danhar1960]

These little things even got around Sydney Harbour.

Danny