Project MOVIESTAR

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My 71 55 had shoulder belts mounted there. Im assuming you guys dont have that down in the states?
 
Three pics to finish up the seatbelt mini-hijack...

A cross section of the mount, with a nickel for scale.
newrust003.jpg


and two reference photos for location.
newrust004.jpg

newrust005.jpg
 
And some bad news...cut the corners off to replace with the straight ones...
newrust013.jpg

newrust014.jpg


No rust on the outer panel, but look what was hiding...
newrust015.jpg


The inner corner was packed with sand, dirt, rust...so I cut out the bad, and treated the inside with POR-15. Will be making several more patches before the corner goes back on.
newrust018.jpg

newrust020.jpg

newrust027.jpg
 
How does por-15 hold up when you weld panels to it? I was thinking of doing this but didn't want to just burn off the por-15 or something.

about as well as any paint. I will be grinding the POR-15 off the specific weld points, and hitting it with a weld-through primer. The heat will damage the paint, but the bulk of the panels will remain protected. It is imperfect, but better than factory protection.
 
And some bad news...cut the corners off to replace with the straight ones...

No rust on the outer panel, but look what was hiding...

The inner corner was packed with sand, dirt, rust...so I cut out the bad, and treated the inside with POR-15. Will be making several more patches before the corner goes back on.

The rear pillar on the '55 is three layers all the way up.
 
about as well as any paint. I will be grinding the POR-15 off the specific weld points, and hitting it with a weld-through primer. The heat will damage the paint, but the bulk of the panels will remain protected. It is imperfect, but better than factory protection.

Or lack of factory proctection...

That is some tough news about the rust in the corners. :eek:
 
And I wanted to say thanks to Jason for saving my truck from certain death.

It's inevitable that my 55 will be a mobile business card for Punish Your Machine when I get it back to CA. Many vintage car lovers here but few craftsmen of his caliber.

The support of this board is really appreciated also. Many times I felt woozy and sick when new rust was discovered during this resto (just ask Jason). But having peeps around who understand what it's like to own a pig really helps.

Thanks.
 
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Elyse,

Take some credit yourself for putting enough value in your Pig to save it!

You have a great Pig - Jason is doing a wonderful job on it...

+1

Without you, that pig would not be in Jason's care. It could still be rusting. You made the choice to save it, and put it in the best of hands.

It is amazing to watch his "Mad Skills"
 
Well, despite the setback, work must go on.

I changed gears a bit, and got back to the roof piece. I am somewhat concerned about cutting more of the body off, with the roof also missing. Getting the roof on will add a little more structural stability, then back to the newly discovered roof issues.

I got the replacement skin up on a workbench, and started grinding and straightening the flanges. I also filled 5 holes on one side that used to hold a roof rack.

Cleaned and clamped. A copper piece or two to help with burn through.
NewRoofholerepairandmountstraigh-6.jpg

NewRoofholerepairandmountstraigh-4.jpg


Filled
NewRoofholerepairandmountstraigh-2.jpg


Cleaned
NewRoofholerepairandmountstraigh-1.jpg


Straight
NewRoofholerepairandmountstraighten.jpg
 
Two observations:
1) Jason has mad skills
2) it looks like Jason goes through a lot of diapers at his house!!!

One would think that working with a film maker would improve my awareness of background. However, those diaper boxes pay for themselves...i store parts, tools, etc. I once made a shade for my mustangs windshield out of one. Plus, think of all the work i get done by avoiding those pesky bathroom breaks:ban:
 
How does por-15 hold up when you weld panels to it? I was thinking of doing this but didn't want to just burn off the por-15 or something.

The underbody of my '73 FJ40 & :pig: is 100% POR15 semi-gloss black. I've welded many brackets & other pieces right beside some cured POR15 & it holds up amazingly well. It'll get a little chalky when burnt. I spoke to a tech at POR15 one time & he said it's rated to 600 deg., IIRC.
 
So, a cleaned up roof skin has got to have a gutter rail to attatch to. I really trashed the rails getting the roof skins off, but that is okay. I have a plan.

Because Elyse has a monster roof rack, I am taking the opportunity to beef this sucker up. I am replacing the bent sheet metal gutters with 1/8 thick C channel steel.

A little comparison of original, and new idea.
feb2010andstuff029.jpg

An afternoon with the plasma cutter trimmed the innner lip for it to fit.
feb2010andstuff033.jpg

Will do both sides, 8 feet of rail replaced with this. Makes it 3/8 inch wider, and there is a slight curve, so I will have to massage the steel a bit to snug it up.
feb2010andstuff027.jpg

And once they are on, I will figure out a way to blend the big boys into the factory front and rears.
feb2010andstuff026.jpg
 
Finally, the weather broke above 50 degrees. I was able to get the inside of the roof coated with POR-15. I also finished the roof inner supports.

I painted up to the overspray marks, still clearly visible on the donor roof. Should provide significantly better protection than bare steel from the factory.
PORroof002.jpg

PORroof003.jpg

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