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Current Page: 11 of 28
Re: FC Fire Dept Truck Restoration
Posted by: Lane66m ()
Date: November 22, 2016 08:25AM

Steve:

Great work on that under body repair.

smiling smileyDo you wanna trade jacks? thumbs up I love the end result of yours. just kidding. When we get warm weather again, I will start cleaning, blasting and painting my parts. I don't have a heated room in my Corvair Center, where I can do this work in the cool months.

Al Lane
Ellabell, GA 31308

1966 Monza Coupe, 110 hp, 4 Spd
1966 Monza More Door 110 hp, PG
1968 Camaro SS Coupe 350 CI 295+ hp PG
1964 Greenbrier Deluxe, 6 dr, 80 hp car engine, PG
1947 Farmall A tractor 15 hp


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Re: FC Fire Dept Truck Restoration
Posted by: SteveInMarietta ()
Date: November 28, 2016 04:55PM


I've begun to receive some replacement body parts, so decided to go ahead and repair a rotted outrigger sill brace. Here's what it looked like before and after removing the undercoating.

The bottom of the brace was pretty well rotted away.

The outrigger sills are the undercarriage supports that extend out to the side rocker panels. This diagram from the assembly manual shows the brace on the left side, although I was working on the mirror image brace on right side.
This is the same area that needed to be straightened as previously described. The condition of this brace is important since it is the position where the van is supposed to be jacked when replacing a tire.

The rotted brace was removed by drilling pilot holes from the back side through the center of each spot weld, and then using a spot weld drill on the front side. There were plenty of spot welds, including four on the bottom.

It was helpful that I could cut the original brace into pieces as I worked to better access spot weld and rip it out. The outrigger sill itself shows some rust, but was pretty solid.

This is the replacement. Cut from a body piece provided by Jeff at the Corvair Ranch. It needed to be extracted more carefully, but the surrounding metal could be sacrificed in this case


Here's the replacement brace welded into place.


and as viewed from the back side.

Those pilot holes shown above were expanded to 1/4 inch, and used to weld the brace from the back side. Additional spot welds were replaced from the bottom and front side, and all were ground smooth.

Just needs to be prepped and painted with POR-15 where needed.

Steve

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Re: FC Fire Dept Truck Restoration
Posted by: larry202br ()
Date: November 29, 2016 01:28PM

Excellent thread. Some of your welds look a little "bronzy". Are you welding or brazing?

1961 rampside with a 65 / 67 110 engine, car four speed.
1965 convertible
1966 Custom two door/four door 180 Turbo.

KC0SKX
Olathe, ks
HACOA

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Re: FC Fire Dept Truck Restoration
Posted by: glivorsi ()
Date: November 29, 2016 02:19PM

Steve- How are you treating the metal between the pieces that you welded together? Are you planning to just encapsulate everything in POR-15? Eastwood makes a self-etching weld-through primer in a rattle can. I used it when I replaced the floors on my '65 vert to protect any pieces that were sandwiched together. It lays down nice and only burns off at the actual weld site.

Greg in Wildwood, MO (part of the St. Louis urban sprawl)

1965 Monza Vert 110PG, Crocus Yellow with black interior and top

2014 Honda Accord V6 (DD)
2017 Honda Pilot (wifemobile)
2012 Chevy Sonic 1.8L (kid's car)
1997 Honda CBR1100XX
2006 Mazdaspeed 6 (no longer own)

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Re: FC Fire Dept Truck Restoration
Posted by: SteveInMarietta ()
Date: November 29, 2016 05:53PM

Larry,
Everything is mig welded; the bronzy appearance is an optical effect from the flash.

Greg,
Only the rusted areas will be painted with POR-15. It is very risky painting unrusted metal with POR-15 unless it is seriously scuffed up. I have seen POR-15 peal off old but unrusted metal that had even been acid etched.
I considered weld through primer, but opted not to since the undercarriage will be epoxy primed, which should do a good job sealing.

Steve

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Re: FC Fire Dept Truck Restoration
Posted by: gregb ()
Date: November 29, 2016 06:19PM

Doing a great job Steve, I really look forward to seeing what your doing next in this thread. You may have mentioned along the way but I didn't see, what are you using to remove the undercoating?

Gregb

Alberta Canada
61 Canadian Lakewood
62 Spyder Triple Black Convertible
65 Corsa Coupe

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Re: FC Fire Dept Truck Restoration
Posted by: SteveInMarietta ()
Date: November 29, 2016 06:22PM

Greg,
Discussion of removing undercoating began on Sept 26 (page 8).
Steve

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Re: FC Fire Dept Truck Restoration
Posted by: gregb ()
Date: November 30, 2016 11:15AM

Thanks Steve, I some how missed that page.

Gregb

Alberta Canada
61 Canadian Lakewood
62 Spyder Triple Black Convertible
65 Corsa Coupe

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Re: FC Fire Dept Truck Restoration
Posted by: SteveInMarietta ()
Date: December 04, 2016 05:40PM


The rear undercarriage and engine compartment have finish paint. It's taken a lot of detail work to clean all the nooks and crannies to satisfaction, making sure all the surfaces were adhesive. All areas that were encapsulated with PO%-15 were sanded with 330 sandpaper.
These are the paints I use (plus appropriate hardeners and reducers)
.
The Omni Acrylic Urethane was mixed to match the FC bed color posted here. The PPG Concept was the only paint that could be matched to the original undercoating color (with some custom tweaking) with a low matte finish. Darn expensive stuff, but coverage is quick and thorough, which is valuable when painting tight spaces, such as inside of rocker panels. After first applying the epoxy primer and allowing to cure an hour, everything receiving undercarriage color was then painted. Here's a few views. First, with original undercoating
.

and now finished
.

.

inside wheel wells
.

The hinge areas are really tight
.

Here's the bottom of the battery compartment; repairs to this were described previously
.

The engine compartment was painted the next day (the epoxy primer can be top coated directly within a 3 day window). I suspect that the Chevy paint shop did go to any length to protect the undercarriage from overspray, but I masked off areas. Here is the engine compartment with epoxy primer and some of he masking.
.

And with the finish paint
.

Speaking of lots of nooks and crannies, the rear engine mount bracket is grueling to clean but looks really nice when painted.

.

Well, now onward to the front undercarriage.


Steve

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Re: FC Fire Dept Truck Restoration
Posted by: cnicol ()
Date: December 04, 2016 05:43PM

Holy Cow! Nice work Steve!smileys with beer

Craig N. Coeur d'Alene ID.
66 Black Monza 4dr, 4.2L V8 49k
61 Seamist Jade Rampside 140 PG
60 Monza coupe (sold, sniff sniff)
66 Sprint Corsa convt - First car! Re-purchased 43 years later
2+2 gnatsuM 5691

+17 Tons of parts

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Re: FC Fire Dept Truck Restoration
Posted by: coleslaw31 ()
Date: December 04, 2016 05:48PM

I could just lay under there and stare at the perfection

South Carolina Upstate



68 Monza convertible 140 4spd A/C (coming soon)
66 Corsa coupe 140 4spd

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Re: FC Fire Dept Truck Restoration
Posted by: gregb ()
Date: December 04, 2016 05:59PM

What Craig said!

Gregb

Alberta Canada
61 Canadian Lakewood
62 Spyder Triple Black Convertible
65 Corsa Coupe

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Re: FC Fire Dept Truck Restoration
Posted by: The Stig ()
Date: December 04, 2016 05:59PM

Very nice work!

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Re: FC Fire Dept Truck Restoration
Posted by: bought1 ()
Date: December 05, 2016 04:57AM

Great job and very quickly to boot!thumbs up

Dave

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Re: FC Fire Dept Truck Restoration
Posted by: igottajob2 ()
Date: December 05, 2016 07:31AM

AMAZING! smileys with beer

Minneapolis,MN

1965 500 Coupe
95HP

Built the 1st week of April of 65 at willow run.
500 coupe. The only factory accessory is a rear antenna.
White with a red interior.
Now black with black and red interior.


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Re: FC Fire Dept Truck Restoration
Posted by: Pedigo ()
Date: December 05, 2016 07:45AM

You missed a spot.smoking smiley

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Re: FC Fire Dept Truck Restoration
Posted by: SteveInMarietta ()
Date: December 05, 2016 08:40AM

Ole Eagle-eye Pedigo! Actually, I need to touch up a few areas.

One annoyance was dirt, pebbles, grit, little sticks, and mud wasp nests in the undercarriage cross-supports, those large, hollow, rectangular braces that support the floor. This stuff would continuously fall out of the various small holes (usually into an eye) and the open ends into the rocker panels. I used the compressor to blow air through the holes with a vacuum cleaner stuck into the ends to clear the supports as best possible, and it took almost an hour to do so, but some cr*p always seems to emerge at will; and some did as I painted. I'll fix those spots later.

Steve

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Re: FC Fire Dept Truck Restoration
Posted by: Pedigo ()
Date: December 05, 2016 03:25PM

I was kidding,Steve. Looks so nice and clean!

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Re: FC Fire Dept Truck Restoration
Posted by: SteveInMarietta ()
Date: December 05, 2016 07:44PM

T, I knew that, but the perfectionist in me (who would have known, huh?) couldn't claim perfection.

btw: Here's a high resolution stencil I made of the air cleaner label.


In theory, paint squeegeed over it passes the image to the underlying surface. But I haven't figured out yet how to make an equally high resolution transfer onto metal with a suitable paint.

Any suggestions?
Steve

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Re: FC Fire Dept Truck Restoration
Posted by: cad-kid ()
Date: December 07, 2016 12:23PM

First impression after seeing before and after is smiling bouncing smiley WOW! smiling bouncing smiley

excellent work!

Jeremy (cad-kid)
Kronenwetter, WI (Central Wisconsin)
SOLD-9-2016 65 Monza 4spd/140
<a href=http://corvaircenter.com/phorum/read.php?1,570615>My 65 Monza thread</a>
<a href=https://www.youtube.com/user/cad0kid>My YouTube page</a> yawning smiley

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Current Page: 11 of 28


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