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1959 356A S/R coupe project chassis # 108625

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  • JTR70
    replied
    Last of the prep work along the top of the new closing wall.
    Click image for larger version  Name:	IMG_9434.jpg Views:	0 Size:	517.1 KB ID:	113349 Excess trimmed and adding in the 90 for the eventual wrap now.
    Click image for larger version  Name:	IMG_9435.jpg Views:	0 Size:	523.8 KB ID:	113350 All set. Been a long road but the entire top run of this wall is now actually ready to be installed.
    Click image for larger version  Name:	IMG_9433.jpg Views:	0 Size:	509.8 KB ID:	113351 Onto a bit more vertical flange correction.
    Click image for larger version  Name:	IMG_9425.jpg Views:	0 Size:	481.9 KB ID:	113352 A touch more lower flange trimming and shaping..
    Click image for larger version  Name:	IMG_9426.jpg Views:	0 Size:	521.7 KB ID:	113353 and plug weld hole punching but its getting dangerously close to final install time.

    Thanks for looking!

    Justin
    Last edited by JTR70; 09-29-2022, 09:00 AM.

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  • JTR70
    replied
    Gusset install with further wall preparation details.
    Click image for larger version  Name:	IMG_9419.jpg Views:	0 Size:	588.9 KB ID:	113343 Forward gusset member plugged in.
    Click image for larger version  Name:	IMG_9421.jpg Views:	0 Size:	575.2 KB ID:	113344 Wall back in to make sure they fit together.
    Click image for larger version  Name:	IMG_9422.jpg Views:	0 Size:	565.5 KB ID:	113345 Wall is allowed to come in where it needs to be with the top of this flange swooping in and laying in against it nicely. All set with no more changes to this piece needed other than some weld dressing. Side note: The twin tack weld detail at the weather strip channel added. All the original gussets received two along here; these replicated right over top of the originals. Back to panel wall prep.
    Click image for larger version  Name:	image_65776.jpg Views:	3 Size:	446.9 KB ID:	113346 Ready to trim away the excess along the quarter window base. Etched in the fold line along the top of this lip first.
    Click image for larger version  Name:	image_65777.jpg Views:	3 Size:	455.5 KB ID:	113347 Need about another 6mm left above the etch line to complete the fold cleanly.
    Last edited by JTR70; 09-29-2022, 08:45 AM.

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  • JTR70
    commented on 's reply
    Thanks again Roy, It was getting closer little by little...

  • roy mawbey
    replied
    Thanks Justin all is clear now , that's a nice repair to have made so easy to have just filled a few holes and not realised what you were covering up ! Looks really strong now!
    Roy

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  • JTR70
    replied
    Click image for larger version  Name:	IMG_9406.jpg Views:	0 Size:	630.3 KB ID:	113329 New patch all stitched in.
    Click image for larger version  Name:	IMG_9410.jpg Views:	0 Size:	593.5 KB ID:	113330 Welds partially dressed with those remaining lower right rust holes closed.
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ID:	113331 Top of the frame now ready to accept the new gusset plate.
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ID:	113332 Gusset mounted for the final time.
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ID:	113333 Once the wall is in the final piece of the gusset can go on. Note the pin holes in the lower left that need filling. Never seems to end...

    Thanks for looking.

    Justin
    Last edited by JTR70; 09-15-2022, 08:59 PM.

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  • JTR70
    replied
    Patching up the holes.
    Click image for larger version  Name:	IMG_9399.jpg Views:	0 Size:	545.2 KB ID:	113323 Making the footprint of the patch as small as possible. Smaller series of holes to the lower right can be easily welded closed with my torch. You'll notice all the pits and divots are topside so it rusted out from the top side inward so there should be no surprise advanced rust lurking underneath the rest of this area.
    Click image for larger version  Name:	image_65762.jpg Views:	3 Size:	595.0 KB ID:	113324 As luck would have it I cut about 3MM too far inward and missed the shoulder of rear torsion housing flange. I would have preferred to have the weld joint supported over the top of it but it was too late by this time. It will work out either way but that would have been my preferrence.
    Click image for larger version  Name:	image_65763.jpg Views:	3 Size:	615.7 KB ID:	113325 New patch of 18 gauge cut to basic shape.
    Click image for larger version  Name:	image_65764.jpg Views:	3 Size:	544.3 KB ID:	113326 Fine trimming and adding in the bend and contour details next.
    Click image for larger version  Name:	image_65765.jpg Views:	3 Size:	514.6 KB ID:	113327 Trimmed, shaped and set screwing into final position.
    Last edited by JTR70; 09-15-2022, 08:50 PM.

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  • JTR70
    commented on 's reply
    Sorry for any confusion there Roy; no, that gusset can't be in the way when those holes are patched. I just wanted to get its shape finalized before I addressed that area. Thanks again Sir.

    Justin

  • roy mawbey
    replied
    Justin, I presume the repair of those rust holes is easier to do if the bolted on section is firmly in place to hold everything in place datum wise. I will be interested to see how you do that.

    Well done again !
    Roy

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  • JTR70
    replied
    Forward Gusset section complete
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ID:	113318 Flange adjustments complete.
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ID:	113319 One more test fit and its all ready to go. Fixing the rust holes in the section its mounted to next.

    Thanks for looking.

    Justin

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  • JTR70
    replied
    Flanging gusset wall.
    Click image for larger version  Name:	IMG_9387.jpg Views:	0 Size:	539.9 KB ID:	113312 Base 90 degree in and trying to mount/shape it into the footprint of the original as closely as possible.
    Click image for larger version  Name:	IMG_9388.jpg Views:	0 Size:	552.1 KB ID:	113313 Initial mounting, now onto adding the lateral flange.
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ID:	113314 Arched lateral flange in and now have my basic part.
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ID:	113315 test fit and all good so far. The last bit of the upper corner has to turn a little fast but otherwise its good to go.
    Click image for larger version

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ID:	113316 Shot of that flange section that has to go in ahead of the wall.
    Last edited by JTR70; 09-12-2022, 09:20 PM.

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  • JTR70
    replied
    New closing wall just about ready for final installation.
    Click image for larger version  Name:	IMG_9382.jpg Views:	0 Size:	566.9 KB ID:	113306 By contrast this side is going to be very straight forward. It fit pretty well to begin with and just had to turn about the last bottom 4 inches of the flange a little sooner here.
    Click image for larger version  Name:	IMG_9383.jpg Views:	0 Size:	505.3 KB ID:	113307 The it was onto shaping this corner against the quarter panel for a tight fit.
    Click image for larger version  Name:	IMG_9384.jpg Views:	0 Size:	484.6 KB ID:	113308 Another test fit. Upper corner and leading edge shaped to suit. This is getting dangerously close to finally going in for good.
    Click image for larger version  Name:	IMG_9004.jpg Views:	0 Size:	709.3 KB ID:	113309 But....its time to switch gears. Part of the interior gusset structure's flange mounts first and is underneath the closing wall's flange. Highlighted here with the tip of that rat-tail file.
    Click image for larger version  Name:	IMG_9386.jpg Views:	0 Size:	628.5 KB ID:	113310 First things first. Finishing the forward gusset wall which I had cut out to basic shape from the remains of the old door skin. Then onto repairing these rust holes on the area it mounts to.


    Last edited by JTR70; 09-12-2022, 09:09 PM.

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  • JTR70
    replied
    Upper flange finally set.
    Click image for larger version  Name:	IMG_9374.jpg Views:	0 Size:	476.3 KB ID:	113300 Forward cap flange complete and replicates as closely as possible the way it was originally installed.
    Click image for larger version  Name:	image_65745.jpg Views:	3 Size:	530.8 KB ID:	113301 Finally got this new upper closing wall to mount and seal into this old body section.
    Click image for larger version  Name:	image_65746.jpg Views:	3 Size:	490.5 KB ID:	113302 This double stepped flanged proved to be one of the more tricky features to dial in correctly.
    Click image for larger version  Name:	image_65747.jpg Views:	3 Size:	664.0 KB ID:	113303 This corner should seal nicely once its all welded up.
    Click image for larger version  Name:	image_65748.jpg Views:	3 Size:	518.7 KB ID:	113304 Now onto the forward flange at the striker. This by contrast is much simpler and fit pretty well right out of the box save for the bottom 4 inches or so where it swings too wide.
    Last edited by JTR70; 09-09-2022, 09:10 PM.

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  • JTR70
    replied
    Finishing and sealing out the front of this upper flange.
    Click image for larger version  Name:	IMG_9368.jpg Views:	0 Size:	386.8 KB ID:	113294 A quick test piece to figure out how to cut and shape this cap.
    Click image for larger version  Name:	IMG_9369.jpg Views:	0 Size:	525.1 KB ID:	113295 For my purposes Trevor had cut this end well short. Added this tail section on to both terminate into the quarter window opening flange and wrap around the backside of it as found when I dismantled it.
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ID:	113296 Another test fit. Rolled tail butts into the window flange as originally; just have to build up the sides to finish this cap out.
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ID:	113297 This new "tail" is a little long but runs along the flange for bit sealing out the wheel well. Some trimming and welding to sides of this cap yet to do but it was taking shape.
    Click image for larger version

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ID:	113298 Closing up the sides and locking in the final shape.
    Last edited by JTR70; 09-09-2022, 08:52 PM.

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  • JTR70
    replied
    Finish out the back corner:
    Click image for larger version  Name:	IMG_9353.jpg Views:	0 Size:	537.7 KB ID:	113288 This two step flange did not lend itself for heavy reshaping in one piece so I cut it into manageable strips. First was setting the mating strip for a tight wrap around fit to seal out the wheel well and eventual water slinging off of the tire.
    Click image for larger version  Name:	image_65735.jpg Views:	3 Size:	483.7 KB ID:	113289 Then the rest of the strips were located and tucked in as tight as they'd go and welded.
    Click image for larger version  Name:	image_65736.jpg Views:	3 Size:	528.7 KB ID:	113290 Newly shaped end all welded up, dressed and heated one more time to tighten up the shape.
    Click image for larger version  Name:	image_65737.jpg Views:	3 Size:	508.6 KB ID:	113291 Once its all undercoated the final presentation should look factory and undisturbed, thats the hope anyway.
    Click image for larger version  Name:	image_65738.jpg Views:	3 Size:	546.8 KB ID:	113292 One more section in the done column. Onto capping the front of this double stepped flange run.

    Thanks for looking.

    Justin
    Last edited by JTR70; 09-06-2022, 11:55 PM.

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  • JTR70
    commented on 's reply
    Thanks for taking the time to look through this Roy and for really appreciating what is actually going into making this new panel fit and mount correctly. I knew exactly what I would be up against which why I did everything I could to save most of the other side. It really is a very complex panel and along with it being a new Trevor Marshall interpretation of this part only adds to the challenge though his panel was still a good place to start.
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