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

[waiting for time]

Checked the corner patches for squareness. The bottom corners must be exactly 90 degr.
They were just off so I corrected this by hammering them straight over the anvil corner.
Then used templates to get the recess in the corner correct.

 

[waiting for time]

Started with fitting everything together.

Cut the extra piece off and had to correct the bottom of the recess.
then welded the first pieces.

 

[waiting for time]

Finished the two reinforcements for the wiper shafts.

 

[middlecalf]

Incredible hammering skills demonstrated

 

[waiting for time]

Incredible hammering skills demonstrated

Thanks.

 

[waiting for time]

On to the other side.
Measure 10 times,

Cut once and grind to fit, ready for welding.

Grinding and sanding and repeat.......

Next I used the tape template to locate the holes. Then measured to find the exact locations.

 

[waiting for time]

Test fitted the new outside bottom on the inside frame.

Fitment Looks good

 

[HighOctane]

you sure are taking this project serious. Respect on the details and time committed to get it perfect.

 

[waiting for time]

you sure are taking this project serious. Respect on the details and time committed to get it perfect.

Thanks.

 

[waiting for time]

Back on the wind screen frame.
detailing the corners.

 

[waiting for time]

Cutting the pieces to fit to each other and welding them together.

Tacking them first, then hammer everything nice and flat

Then fully welded.

and cleaned up.

 

[waiting for time]

Looks pretty similar to the original except for the brown spots and air holes.

 

[tucker74]

Looks amazing man - gotta be getting close on the panel work

 

[waiting for time]

Looks amazing man - gotta be getting close on the panel work

Thanks, I’m just getting started.

 

[waiting for time]

Cleaning the frame before cutting.

It needs a bit more welding later.

All clean.

 

[waiting for time]

Point of no return.

Cut a bit oversized then grind to fit.

The other side.

Nice fit, almost ready for welding.

 

[waiting for time]

Welded.

Ready for the other side.

 

[middlecalf]

Awesome! How’s controlling weld heat going? With all the contours maybe not too much an issue with warping?

 

[waiting for time]

Awesome! How’s controlling weld heat going? With all the contours maybe not too much an issue with warping?

The contours help.
I use my TIG welder on a high setting and melt the rod fast to limit the added heat.

 

[waiting for time]

Second corner made to fit and welded.