1965 Series 2a Station Wagon in Holland

Stretch · Jun 13, 2017

BULKHEAD (partial) DAY NINE

Only a few nano-seconds today (or so it felt) to make the following. Still a work in progress. Might not do what I want...

1965 series 2a station wagon bulkhead making hammer form inner vents1.JPG

1965 series 2a station wagon bulkhead making hammer form inner vents2.JPG

1965 series 2a station wagon bulkhead making hammer form inner vents3.JPG

...Lots of work to be done still...

...will it won't it????

This could be a waste of time.

Stretch · Jun 14, 2017

People here might not know - but may be you do - the thing with home made English wheel frames is that they very quickly develop into some kind of a workshop penis extension (not literally, but a kind of show off piece - what suburbia might call a "talking point" - the sort of thing that gathers dust in a prominent position)...

...I'm trying very hard to resist the urge to fiddle with my new workshop penis extension...

...might even leave some of those ugly welds as a statement of workshop penis anarchy - make it a knobbly one...

Stretch · Jun 15, 2017

In between post for the hammer form =>

I had trouble cutting a sharp angle in the OSB so I've resorted to glass fibre filled filler. I would have bought some metal impregnated stuff but the motor factors was out of stock (I guess the locals are busy trying to foil magnet wielding potential purchasers). I don't expect the filler to last long - it is at least in a position where little forming needs to be made.

1965 series 2a station wagon bulkhead making hammer form inner vents4.JPG

Fairly liberally applied - waiting till tomorrow for sanding

Amazingly I actually found a use for a can of WD40 some (kind but misguided) person bought for me about ten years ago - WD40 is pretty crap useless stuff but here the bottom of the can was about the right shape for a circle I needed to draw...

1965 series 2a station wagon bulkhead making hammer form inner vents5.JPG

Cut a scrap of metal at the right angle so it could be used as a former / spreader

1965 series 2a station wagon bulkhead making hammer form inner vents6.JPG

This is probably going to be a mistake =>

1965 series 2a station wagon bulkhead making hammer form inner vents7.JPG

1965 series 2a station wagon bulkhead making hammer form inner vents8.JPG

I think I should have taken the time to rig up the router and make these corners out of wood...

1965 series 2a station wagon bulkhead making hammer form inner vents9.JPG

...I was thinking of "nu-metal" epoxy stuff which is good but could only find the Bison rubbish at short notice.

I give it a 3/10 success rate. Still I'll sand it tomorrow and see how it goes.

Stretch · Jun 15, 2017

English wheel frame progress - going is slow...

I've decided to stop adding more stiffeners to the frame and just build the bit for holding the wheel / anvil...

...all of a sudden it seems much stiffer than expected - it needs a bit of spring in it so you can jab metal between the anvils. I'm going to give it a go and see how it performs before I add any more weight. At the moment I can still move it about - getting close to the weight where you wouldn't really want to though...

Stretch · Jun 16, 2017

TEE DEE US

I keep finding bits that need welding...

It is times like this when it is prudent to remember the teachings of S club 7

Don't stop, never give up...

rob_bell · Jun 17, 2017

I was thinking more "never give up, never surrender" from Galaxy Quest... lol

Stretch · Jun 18, 2017

rob_bell said:
I was thinking more "never give up, never surrender" from Galaxy Quest... lol

Ha ha - are you an American (or a stealth American)? Galaxy Quest seems to be more popular over there.

I got the "rudimentary lathe" response for something I once made a few years back...

Stretch · Jun 18, 2017

BULKHEAD (partial) DAY TEN

Disaster! Cock up! Nul points...

The plan for making the panel for the backside of the vents was as follows =>

1) Make a shallow indentation so I could see more or less where I needed to hammer

1965 series 2a station wagon bulkhead inner vent first attempt1.JPG

This bit worked (and now forms a basis for plan B which will be implemented next) - just using C-clamps

1965 series 2a station wagon bulkhead inner vent first attempt2.JPG

1965 series 2a station wagon bulkhead inner vent first attempt3.JPG

You can just about see it in this picture =>

1965 series 2a station wagon bulkhead inner vent first attempt4.JPG

2) Next clamp one side of the metal and work from the side of the clamp with a hammer / rivet gun to the other side

(This usually works but this time it ended in a bit of a balls up)

1965 series 2a station wagon bulkhead inner vent first attempt5.JPG

3) Hammer time (!)

1965 series 2a station wagon bulkhead inner vent first attempt6.JPG

The metal work hardened a lot faster than I anticipated - I ended up having to beat seven tons of **** out of it...

1965 series 2a station wagon bulkhead inner vent first attempt7.JPG

...so much so I was worried I was about to bust up the hammer form. Shockingly - especially for those Bison "metal" corners - it all stayed together nicely despite my (manly) pounding...

1965 series 2a station wagon bulkhead inner vent first attempt8.JPG

...as always when you kick the crap out of something =>

1965 series 2a station wagon bulkhead inner vent first attempt9.JPG

It will eventually break.

1965 series 2a station wagon bulkhead inner vent first attempt10.JPG

I got rips in the far crease.

1965 series 2a station wagon bulkhead inner vent first attempt11.JPG

To be honest - it wasn't a shock. I was smacking it so hard I was sure I needed to consider annealing...

1965 series 2a station wagon bulkhead inner vent first attempt12.JPG

...so anyway - lesson learned. Tomorrow Mungo go buy new sheet metal...

...and Mungo use his hydraulic workshop press for plan B (and will not clamp the sides to let them flip up even though in his experience Mungo knows this often causes nasty ripples and creases)

1965 series 2a station wagon bulkhead inner vent first attempt13.JPG

To be continued

rob_bell · Jun 20, 2017

Stretch said:
Ha ha - are you an American (or a stealth American)? Galaxy Quest seems to be more popular over there.

I got the "rudimentary lathe" response for something I once made a few years back...

Hahaha!

You might think so... but no

LOL

But Galaxy Quest is quite a fun movie! It was on terrestrial tele here in the UK a few years back

Stretch · Jun 22, 2017

rob_bell said:
Hahaha!

You might think so... but no LOL

But Galaxy Quest is quite a fun movie! It was on terrestrial tele here in the UK a few years back

Oh I agree Galaxy Quest is good fun, along with others such as Blazing Saddles (for its time!) and perhaps even Top Secret...

Stretch · Jun 22, 2017

BULKHEAD (partial) DAY ELEVEN

(Spent about an hour scratching me bits and decided I need some advice from the guru's over on metalmeet.com)

Second attempt for the inner vent panel on the bulkhead.

The results today depend on whether you're a glass half full or half empty kind of a chap...

...I spent a bit of time marking out roughly where the indentations are going to go

1965 series 2a station wagon bulkhead inner vent second attempt1.JPG

I then repeated the trick with the plank of OSB and the G-clamps for both of the indentations

1965 series 2a station wagon bulkhead inner vent second attempt2.JPG

I then clamped one side (loosely) to prevent too much flipping up and went for it (!)

1965 series 2a station wagon bulkhead inner vent second attempt3.JPG

It had quite a good "initial effect"

1965 series 2a station wagon bulkhead inner vent second attempt4.JPG

But at about four metric tons the OSB under the ram is more or less at its limit - you can apply more force but the movement goes into wood / OSB destruction rather than metal shaping (I'm sure there's another limit where the wood compression will more or less stop for a bit whilst the metal moves but for this situation I estimate it will be in excess of ten tons - the limit on my bench top press)

1965 series 2a station wagon bulkhead inner vent second attempt5.JPG

So if you're a glass half full chap you might say that this is a "good start"

There is a bit of wrinkling going on =>

1965 series 2a station wagon bulkhead inner vent second attempt6.JPG

1965 series 2a station wagon bulkhead inner vent second attempt7.JPG

This can be smoothed out with the metal forming / rivet gun solution so I'm not too worried about it just yet. I am trying to avoid folds forming though.

##########

As an aside I tried quickly just the bare ram on the sheet metal and at three metric tons (on the dodgy gauge) you can mark the surface with the ram so I'm not going to do that any more!

1965 series 2a station wagon bulkhead inner vent second attempt8.JPG

########

So for today - work in progress - off to metalmeet.com to get some advice! (I think I need to break out the plastic hammers)

1965 series 2a station wagon bulkhead inner vent second attempt9.JPG

liam_italian · Jun 23, 2017

I think you'll also need to sandwich the rest of the sheet of metal between two pieces of wood to stop it distorting when your pressing the vent into the metal.

You could also cut away the excess metal from the vent area which should make it a bit easier to press the vent area.

Stretch · Jun 23, 2017

liam_italian said:
I think you'll also need to sandwich the rest of the sheet of metal between two pieces of wood to stop it distorting when your pressing the vent into the metal.

You could also cut away the excess metal from the vent area which should make it a bit easier to press the vent area.

As it turned out that was the advice from the chaps on metalmeet.com

1965 series 2a station wagon bulkhead inner vent second attempt10.JPG

I do like those hole punches - nice clean holes

1965 series 2a station wagon bulkhead inner vent second attempt11.JPG

Rough cut made with aviation snips

1965 series 2a station wagon bulkhead inner vent second attempt12.JPG

First blat with the rivet gun =>

1965 series 2a station wagon bulkhead inner vent second attempt13.JPG

It is coming good - more or less - I have manged to rip a few holes though. I guess I have to breath in and let go and just weld up the mistakes later on! It would have been nice to have done it "good" the first time but I don't have the expertise for that just yet.

1965 series 2a station wagon bulkhead inner vent second attempt14.JPG

I've stopped for today to make sure I don't aggravate an old percussion instrument injury (makes it sound like I used to play the triangle for the Rolling Stones but had to give it up 'cos of a repetitive strain injury...) as those rivet guns can be a bit of a bugger on your wrists if done for too long (!)

I also need to buy some more G clamps (again)

liam_italian · Jun 23, 2017

There is a guy over on Facebook (I know your not it's biggest fan lol) who makes repair panels for series land rovers. He has lots of pictures of his work including the jigs etc he's made to make all the pressings etc, it would be worth your while to have a look at it.

Here are a few of the pictures from his page

Stretch · Jun 24, 2017

liam_italian said:
There is a guy over on Facebook (I know your not it's biggest fan lol) who makes repair panels for series land rovers. He has lots of pictures of his work including the jigs etc he's made to make all the pressings etc, it would be worth your while to have a look at it.

Here are a few of the pictures from his page

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Is that the same chap you posted the link for earlier on in the thread? (I guess so)

As much as I admire his work and the effort involved in making machine pressings this is exactly what I am trying to avoid!

I have no intention what so ever of making these parts more than once (or the few attempts it takes me to do it). If anybody is (crazy enough) to ask me to make something for them then the answer is no - have a go your self!

This is a "wood is good" campaign - use it - abuse it - throw it away...

...I do not want to clutter up my life with even more crap than is necessary. It is already beyond a joke.

Because what ever I make is to be chucked at the end of the process I am avoiding solutions that involve CNC laser cutting of steel plates, for example, which in Holland would probably be hundreds of euros: That would then be an impossible heart wrenching chuck which would involve the loss of more shelf space and the gathering of dust.

I've got to kill the clutter and replace with things that are gonna be used at least once in a blue moon!

Alibro · Jun 24, 2017

Stretch said:
Is that the same chap you posted the link for earlier on in the thread? (I guess so)

As much as I admire his work and the effort involved in making machine pressings this is exactly what I am trying to avoid!

I have no intention what so ever of making these parts more than once (or the few attempts it takes me to do it). If anybody is (crazy enough) to ask me to make something for them then the answer is no - have a go your self!

This is a "wood is good" campaign - use it - abuse it - throw it away...

...I do not want to clutter up my life with even more crap than is necessary. It is already beyond a joke.

Because what ever I make is to be chucked at the end of the process I am avoiding solutions that involve CNC laser cutting of steel plates, for example, which in Holland would probably be hundreds of euros: That would then be an impossible heart wrenching chuck which would involve the loss of more shelf space and the gathering of dust.

I've got to kill the clutter and replace with things that are gonna be used at least once in a blue moon!

LOL, I admire your efforts to do the job yourself as that's exactly what I would try to do (emphasis on TRY) but have you thought of using a harder wood? OSB board is quite soft.

Stretch · Jun 24, 2017

Alibro said:
LOL, I admire your efforts to do the job yourself as that's exactly what I would try to do (emphasis on TRY) but have you thought of using a harder wood? OSB board is quite soft.

To be honest I wasn't expecting the wood to have come away completely unscathed so far but it has.

The OSB is protected by better quality plywood in the areas where I expected trouble - the weakest parts, the corners, are full of that fake metal epoxy stuff that I expected would be dust by now. So far the sheet metal has ripped and come apart before any damage to the wooden construction has occurred.

This is indeed seat of your pants pushing it as far as you can before it breaks stuff - I wasn't expecting it to be so resilient - but this plan A / plan B approach seems to be working so far. Plan C is totally different (the more observant might have noticed that as I've posted a drawing a few posts back)

Stretch · Jun 25, 2017

Like a Magpie I saw something else glinting in the corner of my eye

30 milliseconds between the other stuff =>

M22 threaded bar and nuts being used for English wheel adjusters (some say you need to have square thread profiles but I've gone for a lighter weight thread with finer adjustment - we'll see what's good in the end)

Stretch · Jun 29, 2017

Ever had one of those days where nothing seems to go right?

Well - I've had a week of that!

Here's to next week

Stretch · Jul 4, 2017

Hashtag life getting in the bloody way dot com or wot...

...still arsing about with the English wheel - getting closer and closer to perhaps getting used in anger =>

Top wheel now fitted to a cradle and the rest of the slider mechanisms are underway

{All this welding is getting a bit tedious though and I haven't even started on the chassis}

1965 Series 2a Station Wagon in Holland

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