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1959 356A S/R coupe project chassis # 108625

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  • More spur:
    Click image for larger version  Name:	IMG_7857.JPG Views:	0 Size:	496.9 KB ID:	111748 All synched down into final position. Ready to dismount and seal the inner surfaces.
    Click image for larger version  Name:	IMG_7858.JPG Views:	0 Size:	529.9 KB ID:	111749 Inner surfaces coated and now ready to mount for the final time. Every plug weld hole is drilled to both ensure a tight fit but also to allow the weld to catch an edge for a thorough bond.
    Click image for larger version  Name:	IMG_7861.JPG Views:	0 Size:	473.4 KB ID:	111750 Begin plug welding from the center outward.
    Click image for larger version  Name:	IMG_7862.JPG Views:	0 Size:	491.8 KB ID:	111751 Plug welding completed. Now onto dressing the heads flush for a detail follow up with my spot welder.
    Click image for larger version  Name:	IMG_7875.JPG Views:	0 Size:	572.4 KB ID:	111752 Spot weld detail now completes the spur installation. Also added in a run of spots along the longitudinal where possible at the moment.
    Last edited by JTR70; 08-14-2021, 10:14 PM.
    Justin Rio

    Comment


    • Click image for larger version

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ID:	111754 Onto the next deal.....
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ID:	111755 Splash pan lap joint patch repair. Paper template first
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ID:	111756 Onto to steel
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ID:	111757 Stitched in and now the fun part of dressing all this down.
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ID:	111758 Dressed and followed up with my panel spotter. Gas welded seam detail at the bottom edge replicated. Not completely finished here but done for now.

      Thanks for looking!

      Justin

      Justin Rio

      Comment


      • Upper trunk floor under tank repair.
        Click image for larger version  Name:	IMG_7864.JPG Views:	0 Size:	537.2 KB ID:	111760 I was going to begin fitting the front half of the floor pan but....
        Click image for larger version  Name:	IMG_7899.JPG Views:	0 Size:	573.7 KB ID:	111761 But this car has some upper trunk floor rot so I decided now would be the best time to address that while I have open access to the underside of it.
        Click image for larger version  Name:	IMG_7900.JPG Views:	0 Size:	503.9 KB ID:	111762 This being a coupe and with both longitudinal members repaired structural integrity is secure enough to remove this sub-frame jig. Now is the time as its in my way for those under dash repairs to the trunk floor.
        Click image for larger version  Name:	image_64699.jpg Views:	3 Size:	475.7 KB ID:	111763 Subframe now removed giving the clearest shot at the underside of the needed repairs.
        Click image for larger version  Name:	image_64700.jpg Views:	3 Size:	444.0 KB ID:	111764 Most of the rust damage is to the left side but both upper corners have rust. I know they make this panel new but this one is very savable and besides it would be far more work and time to replace this panel when you consider all the accessory brackets and attachments on the underside of this panel. Patch repairs coming up next.

        Thanks for looking!
        Justin
        Last edited by JTR70; 08-15-2021, 09:53 PM.
        Justin Rio

        Comment


        • upper left corner prep:
          Click image for larger version  Name:	IMG_7905.JPG Views:	0 Size:	581.7 KB ID:	111796 Planning out how much to save and where to make the cuts.
          Click image for larger version  Name:	IMG_7906.JPG Views:	0 Size:	511.9 KB ID:	111797 At the floor I decided to make the break under the reinforcement plate to both conceal and support the eventual weld joint.
          Click image for larger version  Name:	IMG_7907.JPG Views:	0 Size:	520.4 KB ID:	111798 This gets me past all the compromised metal along the floor.
          Click image for larger version  Name:	IMG_7910.JPG Views:	0 Size:	572.9 KB ID:	111799 Removing the remains of the old plate.
          Click image for larger version  Name:	IMG_7909.JPG Views:	0 Size:	454.4 KB ID:	111800 Then it as onto cutting and carefully removing the upper corner. Its pretty intricate and layered in through here so I had to take some time to drill a few spot welds and carefully unpeel this onion to get this old piece out intact as its needed to provide the pattern for the new piece that has to be fabricated.
          Justin Rio

          Comment


          • Part 2:
            Click image for larger version  Name:	IMG_7913.JPG Views:	0 Size:	474.3 KB ID:	111802 Corner section carefully removed. Of course there was additional rot found on the inner wall it was sandwiched to.
            Click image for larger version  Name:	image_64727.jpg Views:	3 Size:	533.3 KB ID:	111804 Still have some remains to clean out before its ready to accept the new piece but I'm close to touching bottom here.
            Click image for larger version  Name:	IMG_7914.JPG Views:	0 Size:	710.1 KB ID:	111803 It took some care to get this now very delicate section out in one piece but the contour and shape info was now too valuable to just hack out.
            Click image for larger version  Name:	IMG_7919.JPG Views:	0 Size:	577.3 KB ID:	111805 Experimenting with some heat and drive axle section as a hammer form. Getting a plan together to build this part cleanly.
            Click image for larger version  Name:	IMG_7898.JPG Views:	0 Size:	650.6 KB ID:	111806 While that marinates in my mind I dug out an old trunk floor /bulkhead section to harvest my patch panels with the needed relief shapes for the floor.
            Last edited by JTR70; 08-26-2021, 10:25 PM.
            Justin Rio

            Comment


            • Trunk floor repair patch:
              Click image for larger version  Name:	IMG_7924.JPG Views:	0 Size:	596.4 KB ID:	111826 My donor is every bit as rotted down low so I'm taking the upper portion and will be flipping it over.
              Click image for larger version  Name:	IMG_7925.JPG Views:	0 Size:	595.2 KB ID:	111830 Because I'm flipping it over the reliefs are now mirrored and on the wrong side in relation to one another. The skinny rib will have to be cut and moved to the other side of the big one.
              Click image for larger version  Name:	IMG_7926.JPG Views:	0 Size:	706.5 KB ID:	111827 Lots of prep work like removing the column brace remains etc. but as you can see the relief shape's shoulders have a gentle taper so replicating these cleanly from scratch would be far more time consuming to replicate versus any prep work needed to make this section work.
              Click image for larger version  Name:	IMG_7928.JPG Views:	0 Size:	474.2 KB ID:	111828 Planning out how much of the donor needed to get past the rot.
              Click image for larger version  Name:	IMG_7927.JPG Views:	0 Size:	562.6 KB ID:	111829 Initial mock ups with donor cut and skinny rib moved to the other side. Its short in front of the fat one so I'm also still adding as well as trimming.
              Last edited by JTR70; 08-31-2021, 09:34 AM.
              Justin Rio

              Comment


              • Part 2:
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ID:	111832 The rot runs up the side so I'll slide this section down and put a 90 in it to cover that.
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ID:	111833 90 installed pretty much finishing off the skinny section prep. Now onto adding a small run to the end of the wide section.
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ID:	111834 Tacking some more on here...
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ID:	111835 Now I finally have my basic patch set. Will finish up the welding on my work table.
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ID:	111836 Cutting the big piece in first....

                Thanks for looking!
                Justin
                Justin Rio

                Comment


                • Patch panel almost complete:
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ID:	111842 Click image for larger version

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ID:	111843 Ready to begin joining these two new pieces together.
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ID:	111844 Just have to establish the final cut line to remove the excess between the two.
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ID:	111845 Cut and tacked. Mocked up one more to time to be sure the ribs still line up.
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ID:	111846 Welding complete to finish out this repair patch.
                  Justin Rio

                  Comment


                  • welding it in finally...
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ID:	111848 A bit of a process but it was now ready to be tacked in for good.
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ID:	111849 Tacked and beginning to lay down some seam welds. This turned out to be a bit tricky as the metals are thin on both sides so it was a balance of getting it hot enough for a proper weld all the while trying to avoid it blowing through which it would do in places at the drop of a hat.
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ID:	111850 All welded in with lots of grinding and a few holes yet to back fill.
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ID:	111851 Have to dress this side as well, again not having the floor pan in my way makes life much easier.
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ID:	111852 Going to grind back a little at a time but in between I'm going to fabricate this corner. That next...

                    Thanks for looking!
                    Justin
                    Justin Rio

                    Comment


                    • Corner at trunk release repair section.
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ID:	111854 Basic profile bends first. Corners had to be more sweeping so I found a pry bar handle that was just the thickness to make these soft turns. I learned from my first attempt to put these bends in ahead of the arched relief.
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ID:	111855 The arched relief was hammered in next.
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ID:	111856 A bit of deformation afterwards to straighten back out.
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ID:	111857 Went ahead and added a pilot hole now to make straightening this lower section easier.
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ID:	111858 flattening and re-bending where needed as it went.

                      Justin Rio

                      Comment


                      • Part2:
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ID:	111860 Deformation all hammered smooth and by sessions end I had my basic shape.
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ID:	111861 Opened up the hole to accept the Original rubber grommet.
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ID:	111862 Cautiously trimming more excess away and adding in more bends.
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ID:	111863 Part was now close enough in shape for a trial fit.
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ID:	111864 A ways yet to go but closing in on the final shape.

                        Thanks for looking!
                        Justin
                        Justin Rio

                        Comment


                        • Upper Corner of floor repair patch:
                          Click image for larger version  Name:	IMG_8005.JPG Views:	0 Size:	532.6 KB ID:	111873 That new upper corner actually has to lay over top of the eventual floor repair section so I set it aside and switched gears to begin paper templates.
                          Click image for larger version  Name:	IMG_8007.JPG Views:	0 Size:	449.3 KB ID:	111874 In steel and trimmed to basic shape with a soft radiused 90 to continue the original profile.
                          Click image for larger version  Name:	IMG_8009.JPG Views:	0 Size:	486.7 KB ID:	111875 I have my basic new sections but as you can see there remains a lot of fine tuning and shaping to get these two to not only fit the car but to also fit and work together cleanly.
                          Click image for larger version  Name:	IMG_8010.JPG Views:	0 Size:	475.8 KB ID:	111876 Just as I was thinking how simple this part was to make I realized that I had huge gap at the vertical wall that I couldn't account for.
                          Click image for larger version  Name:	IMG_8011.JPG Views:	0 Size:	507.5 KB ID:	111877 A quick look over to the right side showed me there was a drop down stepped profile I was lacking.
                          Justin Rio

                          Comment


                          • Part2:
                            Click image for larger version  Name:	IMG_8012.JPG Views:	0 Size:	495.3 KB ID:	111879 Top side view. This shoulder runs down hill and fades as it moves downward witch puts a bit of a curve ball in there. As you can these corner rusted out too; not as severe and without the complication of a trunk release arch but it will need some unpeeling and repair.
                            Click image for larger version  Name:	IMG_8013.JPG Views:	0 Size:	537.6 KB ID:	111880 After some careful templating I settled on the bend lines and began heeling it over.
                            Click image for larger version  Name:	IMG_8014.JPG Views:	0 Size:	564.3 KB ID:	111881 Adding this relief shape definitely complicated things. I had to add the 90 back in just to be able to test fit and my angle was of course off ever so slightly throwing the whole part off. It took 4 attempts of bending and re-straightening to get that sucker to fit right, I was getting worried about metal fatigue. BTW turning that corner down in the step was a bridge too far. I had it bright orange and it still tore apart.
                            Click image for larger version  Name:	IMG_8016.JPG Views:	0 Size:	506.6 KB ID:	111882 It fought but I had good fit before the night was out.
                            Click image for larger version  Name:	IMG_8017.JPG Views:	0 Size:	542.6 KB ID:	111883 Easy fix though...
                            Justin Rio

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                            • Click image for larger version

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ID:	111885 Basic repair sections at last though the upper section still has some work yet before its ready.
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ID:	111886 Floor section ready to install.
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ID:	111887 Installed for the final time and ready to begin stitching.
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ID:	111888 Crude "V-shaped" cutout detail for trunk release clearance replicated. Welding next....

                              Thanks for looking!
                              Justin
                              Justin Rio

                              Comment


                              • Justin, this needs a more than a few words to say how well you have done one this part of the repair. Really exceptional effort to get that all looking as original. I have followed this repair every step of the way and you should be proud of yourself. For any one not ever having attempted this type of work as I have said before so many times ,you make the fabrication of new sections look easy when that is not the case. It takes ingenuity to find and use, metal forming items that will work. I was for the early part of my working life a press toolmaker, all those difficult shapes were machined on to the punch and die and its not easy to replicate those items manually to make it look original. Likewise, you have to understand when the forming is almost beyond what equipment you have at hand.

                                So its looking good my friend !

                                Roy

                                Comment


                                • JTR70
                                  JTR70 commented
                                  Editing a comment
                                  Hello Roy, Thank you for that really nice and thoughtful comment. You're right I had to do some hunting to find various shaped items around my shop that were going to give me a close enough shape to hammer form into. I seem to just squeak by with what I have on hand. If the shapes are small and complicated enough, as these were I'm hard pressed to make it in one piece though that is my intent; but a relief cut and weld is usually the only way forward most times. A dedicated press and die would have been quite a luxury. Thanks once again for your keen and thoughtful observations. Stay well! Justin
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