Re: Slow Progress at Zippy Performance
[Re: Dragula]
#3070569
08/22/22 06:36 PM
08/22/22 06:36 PM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Pretty much make patterns, templates, cut the patches-often slightly oversize, Lay them in place, hold down with screws or clecos, cut through both layers (the patch and the repair area) At the same time but only partially, tack weld while pushing down/holding the patch flush with a screwdriver or similar. Slowly cut and tack until you're all the way around each patch, stitch weld, then grind using anything from An angle grinder to sandpaper rolls/cartridges, to mini (13” belt) sander. Welding and grinding takes some time, fitting the patches has to be right and you must cut into good metal.
Fitzees fabrication on youtube is a good resource for doing this without much in the way of special tools.
I use mig because I have appropriate equipment for sheetmetal and experience with it, but for the highest possible quality I feel that oxy-acetylene with jewler's torch and/or tig (possibly a combination) is most likely the final frontier for larger jobs because the weld is a much softer composition, less stiff, and easier to work with...however the tedious nature of the job will be amplified with other methods.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: ZIPPY]
#3089995
10/28/22 06:31 PM
10/28/22 06:31 PM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Things slowed down undesirably but that's how it goes when your employer fires 3000 people in one week. Two days after the last post, after over 8 years service, I had to start over. A little turmoil resulted. I picked away at the project but tried not to spend any money, and partially failed.
About a month later I got an all-around way better job somewhere else....so time to get cracking again.
One door is race ready, if there is any such thing.
Ended up doing more repairs to the inner, then using a crazy combination of acid wash and blasting to clean it, then a few coats of epoxy. The skin was more straightforward to install than I thought it would be. I can say that AMD door skin really did fit perfectly, the prep issues that I did have were my own fault and inexperience showing.
I expect the second/left door skin to go on smoother, or at least it won't seem like a brand new thing anymore.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: ZIPPY]
#3090001
10/28/22 06:44 PM
10/28/22 06:44 PM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Also prepped most of the right jamb.
I say "most of" because the dash is still in the car which prevents me from completing the backside of the A pillar. I'm waiting until I get the left door off to pull the dash, so there will be less stuff in the way.
You can see what seems to be a rookie error, as I did epoxy a hard line into the surfacer because of the quick tape job, but I actually don't care and it is OK, its only sanded to 220 anyway. The hard line will disappear with another short pass of 220 blocking + the 320 and others coming after will refine it that much more.
Also decided on exterior color and did a couple sprayouts on the cut off door skin to make sure the color really is what it's supposed to be. First basecoat I tried missed the color pretty badly, second attempt just about nailed it.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: AndyF]
#3090025
10/28/22 07:45 PM
10/28/22 07:45 PM
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Joined: Dec 2021
Posts: 1,145 Loudoun County, VA
Brad_Haak
super stock
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super stock
Joined: Dec 2021
Posts: 1,145
Loudoun County, VA
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Looking good. You are really developing some good skills at rust repair. That is a crazy amount of work. Ummmm... what ^^^ said
2021 Challenger 6.4L Scat Pack 1320 100% stock: 1.680, 11.894 at 113.75 (DA 175 ft) weight reduction, wheels, tires, Hellcat air box: 1.661, 11.686 at 115.97 (DA 710 ft)
1973 Challenger 452 ci street/strip [2008] pump gas, DOT radials: 1.454, 10.523 at 126.44 (DA 514 ft)
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Re: Slow Progress at Zippy Performance
[Re: Brad_Haak]
#3090035
10/28/22 08:02 PM
10/28/22 08:02 PM
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Joined: Jan 2003
Posts: 10,037 MN
JERICOGTX
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Looking good Rich! Light at the end of the tunnel now.
69 GTX
68 Road Runner
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Re: Slow Progress at Zippy Performance
[Re: JERICOGTX]
#3090104
10/29/22 02:20 AM
10/29/22 02:20 AM
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Joined: Mar 2003
Posts: 6,334 Heaven
EvilB1Dart
master
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master
Joined: Mar 2003
Posts: 6,334
Heaven
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Keep at it, Rich! Nice work. It'll be done before you know it.
"Any fool can know. The point is to understand"
- A. Einstein
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Re: Slow Progress at Zippy Performance
[Re: A727Tflite]
#3090251
10/29/22 04:45 PM
10/29/22 04:45 PM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Off the subject, you were working at Chrysler/DaimlerChrysler/FCA/Stellantis?
3000 people let go? Hey, I'll PM you rather than dumping my life story out here.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: AndyF]
#3090258
10/29/22 05:10 PM
10/29/22 05:10 PM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Thanks all, going to stay after it in the off season as much as possible. Looking good. You are really developing some good skills at rust repair. That is a crazy amount of work. TY. In younger days, '80s, I remember thinking people who did that kind of work were like old wizards or something. I never thought I would become one of those people.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: ZIPPY]
#3090273
10/29/22 06:22 PM
10/29/22 06:22 PM
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Joined: Jan 2003
Posts: 7,495 Minnesota
Hemi_Joel
master
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master
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Posts: 7,495
Minnesota
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It is amazing how much you are doing. That takes a lot of perseverance. Long live the GTX!
[img]http://i.imgur.com/boeexFms.jpg[/img]31 Plymouth Coupe, 392 Hemi, T56 magnum RS23J71 RS27J77 RP23J71 RO23J71 WM21J8A I don't regret the things I've done. I only regret the things I didn't do. "Wise men talk because they have something to say; fools because they have to say something. ~ Plato"
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Re: Slow Progress at Zippy Performance
[Re: ZIPPY]
#3090615
10/31/22 08:38 AM
10/31/22 08:38 AM
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Joined: Jan 2003
Posts: 13,374 Marion, South Carolina [><]
an8sec70cuda
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Looks great Zippy and glad your job situation worked out!
CHIP '70 hemicuda, 575" Hemi, 727, Dana 60 '69 road runner, 440-6, 18 spline 4 speed, Dana 60 '71 Demon, 340, low gear 904, 8.75 '73 Chrysler New Yorker, 440, 727, 8.75 '90 Chevy 454SS Silverado, 476" BBC, TH400, 14 bolt '06 GMC 2500HD LBZ Duramax
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Re: Slow Progress at Zippy Performance
[Re: an8sec70cuda]
#3090640
10/31/22 10:27 AM
10/31/22 10:27 AM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Stripped the left door. Thankfully The left door structure is much cleaner than the right. Only the rear lower corner needs to be cut out and repaired, other than that it is pretty solid.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: ZIPPY]
#3090641
10/31/22 10:29 AM
10/31/22 10:29 AM
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Joined: Jan 2003
Posts: 17,875 S.E. Michigan
ZIPPY
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Here's the current situation on the right side.
Rich H.
Esse Quam Videri
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Re: Slow Progress at Zippy Performance
[Re: ZIPPY]
#3090661
10/31/22 11:14 AM
10/31/22 11:14 AM
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Joined: Jan 2003
Posts: 10,037 MN
JERICOGTX
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Looks good Rich. Are you using any guide coat for blocking?
69 GTX
68 Road Runner
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