Builds Rebuilding a 40 but no longer in a 1 car garage.

[waiting for time]

Working on the other side. First I will replace the profile piece and then the rest of the bottom.
This is the corner section, the old part looks good but is severely pitted from the inside.

Another section cut out.

and the patch located in its new position.

 

[waiting for time]

Out with the old,

The profile is new here.

and the new bottom set up with the newly made front clamped to it.

 

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In with the new.

 

[middlecalf]

This is so cool

 

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New bottom all welded.

I used the template made from tape to locate the holes.

Hole locations marked.

And the holes made.

 

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Cleaned up the inside and testritten the new and the old outside sections.

 

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Started on the outside frame.
first new part,

 

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Measured the recess of the hinge locations at 6mm.
Took a piece of 6mm flat bar and hammerel the lip over it.

 

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Not happy with the small lip and decided to make new corners, again.
Used card board to get the exact shape of the recessed area.

Then transferred the shape to a new piece of steel.

Then drawn the lines for the surrounding areas.

All lines transferred mirrored to a second sheet for the other side.

 

[waiting for time]

First bend the diagonal up and hammered down on the 6mm flat bar.
Then the two straight bends.

To get the right lines I used the original frame.

put the part under the scale to get the line right.

The lines are completely different than you would expect, this is the best way to get it correct.

 

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Checking the next line after each bend.

You can see that there is a lot going on in this corner.

And the final part.

 

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Making the internal brackets.

And the backing plates for the wiper shafts.

prepping for cutting, not sure how to cut and keep the dimensions intact.

 

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I thought that I had taken more pictures yesterday but I didn’t.
Now for the viewers that are interested how to make this corner I took a lot more for the other side.
It shows how easy it is to make more complicated pieces.
First the flat sheet with the drawing.

I used the brake to fold the diagonal but it could have been done in a vice.

next I clamped the piece on the table with the 6mm flat bar on the back of the folded area.

First I pushed it down by hand followed by some light hammering.

 

[waiting for time]

Next step, hammering the ends of the bend back out. Until the area of the next, 45, bend.

When you hammer these bends flat a lot of distortion is introduced. To prevent this bekommert an issue this has to be limited. Next step using a small vice brake to benduntill the corner.

This is where the distortion har to be mitigated to be able to go to the next step. I use the hammer on an anvil to keep the sheet a bit in shape. If you don’t do this the distortion wil become to big to take out in a nice way.
Now the piece is clamped on the table again and hammered flat over the 6mm part.

At this moment it is easy to shape the metal the way you want it as the stress is mostly taken out by keeping the material flat. The stress that is still in it wil help to gethematiseerd shape you need.

You can see the stress in the lower left corner But that will come out in the next bend.

 

[waiting for time]

Continuing with the next bend.

Just like the previous one this one is hammered over the 6mm piece and then test fitted.

I used the scale to get the bend line as accurate as possible.
At this stage I have already rounded the corners in the profile, this is done by hammering with the corners against the edge of the anvil. You just hammer and move the material as you see the shape forming.
In the next picture you can see the blue bend line just at a different angle than initially drawn.

After cutting out the corner I used the vice brake to set the bend on the side, for this I transfered the line to the back of the piece.

I Then used the calipers to measure where the next bend has to be. The next bend is also a bit off, the lower part is less deep than the upper.

 

[waiting for time]

Next is the interesting bit. As the recessed area is 6mm deep but the bottom lip is only 3mm deep but 3mm above the recessed area.
First the bend line is drawn. Again just off from the initial line.

You can see the left raised area that has to bend down 3mm and the lower area that needs to come up.

Here the left area is bended up where the small part on the opposite side is bended down.

Now the large section is bend back and everything is hammered flat on the anvil.
next the bottom bend is set, this will later be folded over the bottom lip of the inner frame.

After a little bit of massaging and cleaning with acetone this is the final result.

Let me know if you find this interesting, I can show more in the future.

 

[hdjtachtig]

Love it! Inspirational. Keep it coming, I learn a lot by reading this. IIRC you don’t have a panel beaters background right? “Autodidact “. Cool.

 

[waiting for time]

Love it! Inspirational. Keep it coming, I learn a lot by reading this. IIRC you don’t have a panel beaters background right? “Autodidact “. Cool.

Nope, I started doing metal Work on my other 40. Learning a lot from other forums too but most is triCal and error.

 

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Just a little bit of progress, making the inside corners.
Its going to be a Frankenstein repair.

 

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Made the corners fit as good as possible and then used the original corner as hammer form.