lancemb

My 1957 75R - Big Gray

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Driver side front rocker corner is done...almost.  I have to buy a 3/4" hole saw for the two fender mounting holes. 

 

Next I'll take care of a couple little soft spots on the inner rocker, and then the outer rocker repairs.  One spot at the lead joint (you can barely see it in the photo) and the rear corner is rotted.

 

After that, I'll move to the passenger side and complete the rocker repairs there.

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I'm doing my best to knock out a small piece of this every day.  Probably a pipe dream to keep this up, but it keeps my momentum up...and helps me keep on schedule with projects moving.

 

As I moved to the hole in the driver side rocker, I had to burn out the lead so I could weld to steel after cutting the hole out.  When I melted the lead out, a second hole appeared, almost as big as the original one next to it.  So for this evening, I took care of the first hole.  I'll save the other one for tomorrow.

 

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Edited by Smartin (see edit history)
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It's reassuring that you're finding weldable metal on either side of the holes though, except the one bonus hole.  I was afraid the whole rocker was going to be soft.

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Both holes at the lead joint are fixed.  I moved on to the wheel well corner.  The hole kept getting bigger as I cut...finding more really thin metal.  Finally, I was able to get to some solid metal to weld to.  I ended up cutting a piece of the wheel opening out of the parts car we have here.  It helped with the compound bend around the edge of the wheel opening.

 

Of course, as I was laying down grinding, I found another spot about 8" long where the pinch weld is at the rocker bottom.  That is next.

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11 hours ago, Smartin said:

 

Of course, as I was laying down grinding, I found another spot about 8" long where the pinch weld is at the rocker bottom. 

Might want to the rest of that area along the rockers while down there if you can...looked suspect to me!

 

It's really looking awesome, though!  Keeping me inspired to finish the car!

Edited by lancemb (see edit history)

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I did some poking and the rest of it looks ok.  

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Passenger side quarter was a real mess, along with the rocker.  A lower quarter patch panel was provided with the car, but it was a hokey aftermarket stamping that didn't really even line up with the body lines or openings at the door or wheel.  I did, however, use the wheel opening corner and lower rocker area to patch the quarter panel.

 

The rear trick was to make sure that the bottom body line of the quarter remained straight with the rocker panel as it ran toward the wheel.  When I cut out the bad spots in the quarter, it sprung out toward me.  It was a real challenge trying to measure and cut, mark, measure again, cut, mark, etc...trying to hold the quarter in place.  I ended up using a 4' straight edge to make sure it stayed true.  Once it was tacked in place, I could go to town with the repair.  As you can see, it looks a but sunken and lumpy where the repair was made.  If could have gotten a hammer back there to work it back out with a dolly, that wouldn't be there.  But there just isn't any room.  Even with taking my time and cooling with compressed air, the panel warped a bit. 

 

I am currently working on the joint where the lead seam is at the back corner of the door.  The repair ended up being about 8" in length after the bad metal was cut out.  I have already repaired the inner rocker here, and welded the outer rocker together with a patch.  I have one small 2" square hole to fill on the bottom side of the outer rocker....then I can move to the rear wheel wells.  They are a real mess.

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On to the wheel wells...this repair has to be made on both sides of the metal.  There are actually two layers of metal in both of these spots.  This is the passenger side...the driver side is the same way.

 

This will also take care of all the rust on the body shell.  Let's not talk about the doors, though.

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Did you use a torch to heat up that undercoating before scraping it off?

 

Amazing it rusts out with that stuff on it.

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Yes I heated and then scraped it right off.  These are seams in the sheet metal...and. Horrible spot for a seam, for sure.  Very common spot for these to rust.

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So, after receiving the car back about a month ago, I've been busy with Chrismas stuff and also doing some organizing in my garage to make some elbow room. 

 

Finally, I was able to spend some time with the car today and scored a small victory.  I got the rear end loose and ready to roll out.  Unfortunately I was not able to get the rear end up high enough to roll the axle out with the tires on it.  When I get the next day with it I'll remove the wheels and put the axle on a wheel dolly or floor jack and roll it out.

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Let me see if I have this right, you sold the black Roadie to help fund the resto of this two door...

 

Is there anything happening with the convertible? Is it somewhat like my Roadie convert, collecting what parts you'll need when the time comes? 

 

I'm pretty sure you'll have the two door finished before my Limited but I'm going to give it an honest try to keep up.

 

Happy New Year Sir. 🥳

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3 hours ago, dei said:

Let me see if I have this right, you sold the black Roadie to help fund the resto of this two door...

 

Is there anything happening with the convertible? Is it somewhat like my Roadie convert, collecting what parts you'll need when the time comes? 

 

I'm pretty sure you'll have the two door finished before my Limited but I'm going to give it an honest try to keep up.

 

Happy New Year Sir. 🥳

Well, it so happens that the funds from the black car will probably go more toward the 76C, as the coupe will receive more time than money for the next year.  I will provide a short update on the convertible...

Edited by lancemb (see edit history)
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16 hours ago, lancemb said:

When I get the next day with it I'll remove the wheels and put the axle on a wheel dolly or floor jack and roll it out.

Put down some cardboard and roll it out on the drums...

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If you have wheel skates, set the drums on them and roll it out.  Or just drag it out like a caveman.  I assume you're going to be detailing it, so you'll have to be careful putting it back in.

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Maybe deflating the tires will help get it past the rear of the car.  If not, wheeled dollies with the wheels off. 

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I have a couple cheap wheel dollies, so I think I'll remove the wheels and use the dollies.

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Well, I got the dash home from the parts car (one that I am using part of frame for convertible).  I had originally planned to use the dash pad and steering wheel for the coupe, and a few other pieces.  I had also thought I might be able to use the dash from it since the coupe's is so rusty on the surface, but wasn't so sure that it was nice enough to use it as-is.

 

After cleaning it up, I have decided it is way too nice to redo.  With just a few minor flaws, mostly on the very bottom, I'm going to use it as-is without repainting it.  I may lightly touch up a couple spots at most.  I would never be able to match the color better than original!

 

The chrome cleaned up pretty nicely too, but I will probably change out or redo a few of those pieces since I have it easily accessible.  If the dash was already in the car though, I wouldn't remove any of it as it's too nice.

 

Pretty excited about this!

 

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I finally got the axle out of the way yesterday.  That thing is heavy!  After that I removed the shocks and springs to open up the rear area completely.

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I then spent the rest of the day cleaning up the frame and floor pans.  I will probably spend another full day further cleaning up welds, removing penetrant residue in a couple places, and propping body up.  Then on the next day I get, it will be paint time.

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Big heavy axle and torque tube!!  Glad you got it out from under.        

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On 1/21/2020 at 8:37 AM, lancemb said:

I then spent the rest of the day cleaning up the frame and floor pans.

 

What method(s) are you using for that cleanup?  That job is on my to-do list, albeit somewhere near the bottom, as it's a miserable task...

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43 minutes ago, EmTee said:

 

What method(s) are you using for that cleanup?  That job is on my to-do list, albeit somewhere near the bottom, as it's a miserable task...

 

It is certainly not a joy.  Having a lift makes it tolerable, but it's still a rain of rust bits.

 

At some point early last year or year before, I power washed the underside.  This removed the vast majority of dirt and grease.  Now that's it's patched, my primary method is just old-fashioned wire brush to remove any heavy stuff.  Most of the floors are pretty smooth after doing this. 

 

Next, I just need to remove spots of rust penetrant I oversprayed where further disassembly has occured, and a few spots of dirt I'd missed previously.  I'll use the POR-15 clean and prep to remove the penetrant.

 

Finally, I'll apply POR-15 sealant to seal the surface rust (and it will smooth the surface a bit), then top coat it with paint.

 

Finally, I will apply undercoating as original, much of which is still on the inner rocker panels.

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11 hours ago, EmTee said:

 

What method(s) are you using for that cleanup?  That job is on my to-do list, albeit somewhere near the bottom, as it's a miserable task...

I should also mention that at the very beginning, I spent about a day excavating everything (especially front suspension) with a scraper and screwdriver, assisted by degreaser, prior to power-washing.

Edited by lancemb (see edit history)
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I found a few hours today, so I got a head start on my next task.  I got the body lifted entirely off the frame and slipped the old rubber mounts out.  I should have plenty of access to the top of the frame and the areas of floor above it.

 

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