1962 Vauxhall Victor FB - Making Panels

Got the last bit of that rear lower repair done today



The inside bit needs making and fitting to go in here






I kept the bit that came out so I could use it as a template











Then cut out with my New Throatless shear that I got for Christmas, Santa must have got my note ;D







and drilled the holes







and started to bend up







what you cant really see from the photos is that the flange does not run straight along the panel, it is more like a gentle curve, and then the more pronounced curve at the end

This means it will be harder to form, so after I bent part of it on, I slid the piece along and did a bit more







and then used the dolly on the really curved bit







and there you go








buts thats not it, because the flange runs along a curve then the material naturally wants to curve also, so when you look at it from the side, then it is like this







the flange needs to be shrunk to pull the panel straight again, we could use the shrinker stretcher, but we wont



Instead we will hammer down onto the edge of the flange against something hard and flat








this flattens the panel, but causes the flange to pucker








so then we shrink it with the rawhide mallet against the dolly







these steps were repeated at least 10 times, until it was flat









I left the very end bit as that is supposed to be curved









so bend the end up









and a bit of tweaking to get the flange at the right angle and we have this







tried on for size







welded








and dressed off








the dressing was never going to be perfect as I could not get to the rear of the panel, to push it out as needed when tacking it, but as its under here out of the way, then it will be fine



Fingers crossed, I think that is the last of any panels that need to be made, just a couple of small jobs to weld and clean up and then drop the rear axle and prime the bare metal. oh and a repair to one of the front wings

Quote: 'the dressing was never going to be perfect' You kidding? All the metalwork is perfect!!!!

Generally drill out the spot welds where I can, then split the joint with a small cold chisel

And then when I need to cut a panel, I use the 1mm thick cutting discs for slicing through them, they cut quickly and don't cause too much damage. They don't last that long either, but it seems like a worthwhile trade off.

I found it's really easy to break those 1mm discs if you use too much pressure or if it jolts - then you're picking bits out of your teeth - so I always like to have lots available. Getting better now though, I don't break them as often.

I think because it cuts so fast the temptation is to really load the disc up to make it cut faster, but this eats the disc up too.

EXTRAORDINARY!

^^^^^^^ Thats a Huge thanks to everyone who voted for this thread as thread of the year 2009

and I promise to try to keep it up for 2010

Thanks Grizz, nice to meet you yesterday

Totally deserved Tony...... totally deserved. As I said before, a real treat to see your work. Massive thumbs up from me!

PaulH

This is that photo of the little rubber thing that fits in the 2 smaller holes






the small pin goes in the small hole and the rubber strip covers the larger hole, it must be to let water out.



Meanwhile took the rear axle off yesterday







and stripped it down to save space







Then today had a bit of a poke underneath and found this on the side of the spare wheel well







so cut it out







made patch







clamped







Tacked









welded







and cleaned off







then went to look at the passenger side sill, pic from earlier








cut a strip of steel and bent it over a bit of round bar, purposely overbent







then opened it out with my hands








it was overbent so that it would form the correct shape when opened back out






then trimmed down and welded in







and cleaned off









So now apart from a little bit of cleaning off to do on an earlier repair, then I think this is the last of the welding on the shell, hopefully tomorrow I will get the bit done on the front wing then that will be it apart from the primering to do


Gordon and I were talking on the way back from the Ace Cafe on Wednesday and we are determined to get the car at least to "rolling shell status" in time for us to take it down to the Vauxhall Opel Show at Billing sometime around July, so if any of you go to that, we will hopefully see you there