A-pillar finished

What working on a Sunday? Well this working is kind a relaxing to me.

 The first thing I did was finish welding the panels I tacked in.

 Then Those welds are ground flush.

 Then my attention turned to the firewall. On the bottom near the floor there were some cracks. I welded them. And I also removed some dents on top of the bow you see below.

 I also made a plate with a bracket for bolts welded on  to replace a big hole where ones was an anchor point for the fender reinforcement. The hole was cut out larger and the plate was bent and cut to fit. Al this was done after I took some measurements son I could mount it to the exact location.

After fully welding the welds were ground flush.
And then all the bare metal was sprayed with a protective coat of paint.

Rolling frame

Today I made a frame with wheels so I'm able to move the cabin around.

I made it sturdy enough to give it good support so it will not bend the cabin.

Making the curb

Yes. After my car was repaired I had some time left to do some tinkering.

 Before I can resume to the metal work I need to know how the lines are coming out with the door. So I installed the door and did some aligning to try to get the gaps even. For know The lines of the panels are good. Just the height opposed to the door are a little bit low. The low spots are marked and the measurements are made to correct this ones the door is removed.

 So next I installed the fender to see where my lines are and what the curb of the rest of the panel needs to bee.

The Fender was then removed and a piece of metal was shaped by hand and using the bead roller and stretcher. Then the part was tacked in place making sure that the curve follows the line of the door.

 The fender was installed again to check the gap between the panel and fender.

To close that gap I had to make some cuts and weld in some pieces of steel.
The next step will be removing the door and fender and finish weld the entire panel.

Making more new parts.

Today I started early. The part I tack welded earlier was welded grounded and hammered to flatten it again.

 I then applied some galvanic paint to protect it from rust.
On to the next part. This part is part of the door post , the underside where the bottom hinge is attached. This part was cut out earlier to give better access.
The bottom is almost rusted away.

 After some grinding welding and forming it looks much better.

 It also got some protective paint. Next on the list is the part to witch the outer skin is attached and to witch the fender is bolted to. As you can see the bottom is almost completely rusted away.

 And this is how the part looks now before paint.

 Next a piece of the floor and firewall are cut out. They were rusted trough.

 This is what the repair looks like.

 Then it was time to weld some  parts to the cabin again. I started with the bottom of the door post. It is tacked in place and alligned.

 Next is the inner plate that I made as first. Tacking it in place and finishing the welds.

 And then the last part to witch the fender is mounted. This piece had to be cut again to make it fit to the fender and car. After the welds are finished this is what it looks like before paint.

 This is a view from the inside. There are no more holes.

 So next I started with the fabrication of the last part. The outer skin. After some cutting forming and bending I tacked the first piece in place.

The next piece will be for a later date. And it needs to be checked with the door it should align perfect before finishing the welds.

Making a new part.

The piece I welded in yesterday is now connected to the floor with a small piece of metal .

 The seems are fully welded and ground flush.

 The piece that comes now is badly rusted and already removed. I took a grinding wheel and cut the bad part out. Then i traced the surroundings on new metal and cut it out.
Next I made the reinforcements in the new plate with some pounding on a flat rounded bar.

 And then the 2 good pieces are tacked together. Finishing the weld will be for a next day.

The first cut.

Today I unloaded the truck cabin from my trailer and set it on my bridge.

 So the next thing I did was checking out the damage. At work a college of me did already do some work. Some panels were already cut out.

 Some are rusted away.

 Others seem to be drilled to remove a dent?

 Others are almost rusted completely trough.

 My coworker did cut some parts out on the drivers side.  He also cut loose the A-post and it was already showing some sagging. So I Welded in some braces.

 Then I removed 3 more parts at the A-post so I have room to work.

And then I cut a piece already prepared by my coworker drilled some holes and tacked it in place.
So the first piece of the repair is in.

The arrival.

Today I brought some work back home to me.

 These are the cabin, fenders and doors of a Chevy Pick-up that needs some welding.

Al parts arrived without a problem.
With in a few days we will unload and start the restoration.