Builds Rebuilding a 40 but no longer in a 1 car garage. (2 Viewers)

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Lately I have been cleaning and organizing the shop as every project turned into a struggle of creating room and adding things to make life easier.
one of the thing that was taking floor space for a couple of months now is the front axle. I have been putting off taking it apart as this is, well every one that has done it knows...

So far one side is taken apart but I can’t get it to turn to be able to take the shaft out.
something is stuck but I can’t see what it is.
Attacking the other side now to get it moving.

 

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This stuff is nasty, the left front bearings are completely seized.

It took a BFH to get them out.
inside of the axle was not to bad considering the wheel bearings.

At least I got something done on the 40 again.
just going to clean it a bit and store it until it is time for the frame.

 

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Back to the front wind screen frame.
Bottom of the outside frame

Not much salvable here.
started with profiling the flat and bottom part. Used the bead roller to get the two offsets in, the bottom one is deeper than the top one.

on the bottom the lip is folded, this is also done with the bead roller. Slowly bring it over 10 to 15 degrees at a time until it is about 90.

next I cut a bit thicker metal for the two recessed corners where the hinges are mounted on. A bit of hammering and bending wil make them see my way.

 

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Shaping the corners.

 

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continuing the lower front to the full with of the frame.

getting the shape similar to the first piece is not that easy.

 

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Making the corner complete.
I use tape to get the missing piece in the correct shape and with the amount of material needed.

drawn out with some extra“s for around the corners.

 

[DSB345]

AHHH!

Making the corner complete.
I use tape to get the missing piece in the correct shape and with the amount of material needed.
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drawn out with some extra“s for around the corners.

 

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Shaping, grinding and welding

Fitting the parts together. At this stage you just want them to be in the same ball park.

Slowly getting the shape.

 

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Making the fit better.

3
Time to tack them together.

and test the fit on the original frame.

Looks to be a decent fit.

 

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As you guys like pictures, making the mold.

the advantage of having a 2 piece window frame is that you have a second part to fit the first one on.

 

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I was not happy with the recessed corner and made a new one.

And made the other side too.
first the basic shape.

next I made a template for the profile shape.
here is the profile fitted in the opposite frame section.

And the profile on the front section.

 

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The front top part of the lower cross section of the wind screen frame made. try to read and understand that after the first read.

Luckily we have a picture.

here it is positioned on the inner frame.

 

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Fitting the two parts together and drawing the cutting line.

Clamping, measuring And cutting to size.

The two parts fitted and clamped to the table.

Tacking and fitting.

 

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Next part of the puzzle.
corners, fitted the pieces in their approximates spot.

Deciding how to fill the gap.

Gave it a go with the bead roller and the shrinker/strecher.

 

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Started on making the new pieces for the bottom of the inside frame.

Stil undecided on where to cut and what to replace.
there are a few sections with a challenging ridge on the inside corner that are thin.
Figuring out how to create that ridge.

 

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Started with the first patch of the ridge.

Cut it out and welded the new patch in.

it needs some hammer work but that is for later.

There are a few more area’s with the same issues to go.

 

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As most of the bottom will be replaced I need to have the final position of the holes correct.
therefore I did the tape trick again. Taped up.

And template drawn.

 

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Small update, replaced onesie of the ridge.

I found that the first patch was in crooked therefore I cit it and straitened it out with a steel bar. Then welded the opening with a few tack welds. Next I brazed the gap.

Here you can see the corrected part

And the new bottom patch clamped in place ready for marking and cutting.

 

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Cut the patch to size and tacked it in.

Outside patch fits on.

And the tape template on for the position of the hole.

 

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Creating the holes.
After locating the position of the larger hole vertically the horizontal part is located by extending the lines from the other hole.

Drilling pilot holes.

I used a step drill to create the end holes, then cut the space in between using a grinder.

Then I used different grinders to finish the horizontal lines and a grinding cutter to finish the round area’s.