Can of rusty worms

[Glenwood]

Checking the gaps

Checking the height against the door.

 

[Glenwood]

Getting ready to scribe a line for final cut.

The patch isn't formed quite right. Hoping some hammer and dolly work will correct this.

 

[Glenwood]

Scribed and ready to cut.

A little better after some dolly work.

Pretty tight fit and almost ready to tack.

Staring to look whole again.
Time to cook dinner, so I'll have to get back to this. With the wife on afternoon shift catching bad guys, I'm the chief cook and bottle washer!

 

[Glenwood]

Starting to stitch this up

The width of the Sherman patch is a tad wider...like about 3/16". I had to massage the fold near the windshield a bit to get it to match.

 

[Glenwood]

More exciting welding pics!

blowing through here and there...luvin the rusty metal!

 

[Glenwood]

not looking too bad.

Checking for high spots Time to fix this mess that was hidden by bondo!

 

[threewood]

That's some good fabrication and welding. Blow through is a pain in the butt alright but it looks like you have it under control.

 

[Glenwood]

pretty pitted but I think weldable.

Fitting the new piece after folding on the vice. Trying to get the curve right.

 

[Glenwood]

That's some good fabrication and welding. Blow through is a pain in the butt alright but it looks like you have it under control.

I guess it's to be expected with pitted metal but I'm getting more sensitive to the sounds and weld puddle changing when it's about to blow through. Getting a little better one day at a time! Thanks for the kind words...much appreciated

 

[Glenwood]

Dot, dot dot...planish & grind! oh hum...pretty exciting lol!

Checking the fit before cutting the lip for the brake cylinder bracket.

 

[Glenwood]

This area needs massaging to make a better fit like the original.
I'm worried about the angles of the patch as they are no where near the original. Although this area is covered by the trim, the windshield might not sit properly. If I could find a small hammer, I might try a little dolly work to sharpen the edges.

Had the guys at NAPA match the paint. Looks pretty close to me...Maserati Blue something or other!

 

[Crumley]

Glenwood, looking good. The panel welding becomes a knack that is "learned" by doing (heck I am still learning). And by making mistakes. Learning the proper sound (when wire welding) that the tack/weld makes, how long molten puddle can be maintained before blowing thru and stretching the metal afterwards. Then grinding without taking to much metal off....lol.
Again keep at it and you will be driving the convertible before you know it.

 

[Glenwood]

Thanks Crumley. I found some time to massage that cowl patch some more today. Looks better now. I'll post some pics later...beer time now!

 

[miller]

Well deserved beer at that! Coming along nicely...great work!!

 

[Glenwood]

Thanks Miller...switched to some single malt tonight!

 

[Glenwood]

The folds at the windshield lip on the patch aren't as deep as the original and I'm concerned the glass won't seat properly. The problem is how do you refold this area without a machine?
I figured I needed some small steel blocks to rebend it in small increments.

 

[Glenwood]

A couple of large nuts on some vice grips worked pretty good! I followed with some hammer and dolly work to flatten the top edge.

 

[Glenwood]

Now I had to find a way to get the outer lip of the cowl patch to fit the contour of the lower cowl. First I bent the lip a bit with vice grips and then clamped it to suck it in as I hammered it gently into place. Fits pretty good now.
The lip around the windshield looks much better.

 

[Glenwood]

Time to fix the fender clip mount on the passenger side. The metal is week and tore when I tried to remove the fender. It's a pita to weld in a little patch in this pitted metal but turned out ok.

Dremel comes in handy for these tight spots!

 

[Glenwood]

The cowl is so much closer to being put back on, but I don't like the wiper area on the patch as it's not formed very well. I'm thinking about welding in the original but I'm concerned it will make it look worse with the welding etc. Maybe more scotch tonight will help me work up the nerve! lol