Ol' Rusty - FB/EK Sedan

Post photos of your pride and joy, or updates on your rebuild!

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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Welded. A bit wonky but I hope the actual bailey channel will have a bit of give.
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More silver paint to finish. But will go back darker to match dash before refit.
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On to the rear channel guide.
Happens to fit perfectly over yet another piece of hardwood decking.
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Folded new metal over the hardwood form. Using the old metal to trace out where to cut and grind the new piece.
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Bit of manipulation and old and new should marry back together.
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Good as new(ish)
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
Blacky
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Re: Ol' Rusty - FB/EK Sedan

Post by Blacky »

Holy weaver, I would have just slapped on a few coats of paint and reused those guides :shock: :shock: love your work mate :thumbsup: :thumbsup:

I have a couple of quarter vents to refurbish on the off chance I ever get back on to the 2 door , got some of this to come :)
When you're faced with an unpleasant task that you really don't want to do, sometimes you just have to dig deep down inside and somehow find the patience to wait for someone else to do it for you.


Foundation member #61 of FB/EK Holden club of W.A.
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

I'm speechless Scotty....

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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

As you may have guessed - I don't have much work on at the moment! Even I'm surprised at how much I have done recently. When it's condensed down into a few posts it seems relatively quick but that was done over weeks, bouncing around other tasks, trials and ideas that may show up in the future.
Brett kindly sent me a replacement door release mechanism, so I think these front doors are pretty close mechanically to being finished. Everything goes into a plastic tub for now awaiting future paint and re-assembly.
Dave's Orange Betty EK Sedan has got me inspired to get stuck into the fuel tank. Brett also sent a set of front seat mounts for a Subaru passenger seat mount so playing with that. Still got to finish the rear boot seal channel which have been neglected for a while.
Then there is everything else that needs to be done! Ticking boxes.
Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
Blacky
Posts: 12428
Joined: Tue Jul 20, 2004 8:58 am
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Re: Ol' Rusty - FB/EK Sedan

Post by Blacky »

It’s like eating an elephant, at times it seems impossible but just keep taking bites and you will get there in the end 👍
When you're faced with an unpleasant task that you really don't want to do, sometimes you just have to dig deep down inside and somehow find the patience to wait for someone else to do it for you.


Foundation member #61 of FB/EK Holden club of W.A.
Orange Betty
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Re: Ol' Rusty - FB/EK Sedan

Post by Orange Betty »

Amazing work Scott

Dave
62 EK Sedan in slow progress
In the Shed
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Re: Ol' Rusty - FB/EK Sedan

Post by In the Shed »

Great work…….. again, you’re the master of multi tasking Scott. A skill I have yet to acquire 🤔

Stephen
A day in the shed beats a day at work!
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Thanks for the support! Its been a month so time for an update.
Inspired by Dave's Orange Betty EK Sedan, I decided it was time to tackle the upright brace. Decided to brace the panel around the upright, so I could use the existing boot rubber gutter as a guide to line things back up.
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Cut out most of the rusted floor, drilled out some spot welds and prised the brace off the cross member with a cold chisel.
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Then decided the only way to easily weld the brace to the cross member was out of the car, so I cut a bit of the cross member out as well as it too had a bit of rust. This is what needs to be replaced.
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Made up a paper template for the cross member fix.
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Used a bit of scrap to create a profile for the replacement. Bent up the replacement but didn't take any pics of that. Only tricky bit was the drain hole which I did the same as the rear quarter replacement.
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Meanwhile, made up a new bottom for the brace.
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Soaked it in the citric acid bath that I last used for the chrome work on the door quarter vents. Guess that is a fine layer of copper? Wiped off with my fingers.
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Compared my new brace with the brace on the other side and decided there was not going to be enough meat to spot weld to. Also couldn't work out how I was going to fold those tabs and get it to line back up. So I cut the bottom off and made a new one, scribed a cut on the brace with both the new base and the brace in position, crossed my fingers, cut, and started welding.
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Traced out the new foot of the brace onto the new, folded cross member replacement, and drilled for plug welding.
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Splash of weld through primer and plug welded the two bits together.
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Then trial fit. After a bit of manipulation to make sure it all line up.
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Plug weld the brace to the patch and the patch to the beaver. Then stitched the patch in along the two sides from the bottom.
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Stitched the patch in to the top of the crossmember, and attempt to do the sides. Really is just not enough room to get the MIG in here. Tried grinding off the gas shielding nozzle at 45 degrees but it didn't help much. Haven't dressed these down yet, might have another crack, or could cut open the bottom of the cross member and weld from there (still don't think access with the torch would improve), or maybe I should just buy some JB Weld and move on.
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Dress down the welds under the car, and while I was there finally dressed the welds around the rear quarter repair which I never got to. Spray on some easyphos and time for the next challange.
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

Wel done. Welding underneath is a bugger, isn't it?

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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Not on a rotisserie!
Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

Very good point.


FB ute fixer upper, EK van on rotisserie
getting my FB ute on the road
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Next. Back of the car is a bit of a mess. Full of bog. Wire wheeled it out a while ago, cleaned it up and thought I'd just try and fill the pin holes as it's hidden behind the bumper. Fail. Just blew bigger holes.
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So used a profile gauge to cut a template and then got the powerfile into action to build a die out of hardwood.
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Lots of lines on a bit of 1mm steel and into the press.
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A few passes later.
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Bit of massaging to tighten up the profile and it's a good fit. But it is curving out instead of in.
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Traced the existing curve of the car onto a bit of angle, and used that as a guide. This is what it was like before the first pass in the shrinker.
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And after one light pass....
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Into the stretcher to undo my handy work.
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Needed a bit of work on the profile which opened up with the shrinking. Lay the replacement over the top of the old and scribed. Cut. Sanded to fit. That took a while to get a nice tight fit.
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Tacked.
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Weld, grind and sand. Now the rest of it looks even more like crap.
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
Blacky
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Re: Ol' Rusty - FB/EK Sedan

Post by Blacky »

I always enjoy your posts mate , love how you turn out quality work using no high dollar equipment 👍👍😎
When you're faced with an unpleasant task that you really don't want to do, sometimes you just have to dig deep down inside and somehow find the patience to wait for someone else to do it for you.


Foundation member #61 of FB/EK Holden club of W.A.
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