'37 Dodge sedan

One of the benefits of my job is being able to use the machine shop. I have access to a couple Bridgeports, various lathes, a 4' stomp sheer, a 4' finger brake and other specialty tools that I wouldn't otherwise be able to use. I took advantage of my lunch break today and bent up a few panels to make my rockers out of. Reproduction rockers are available, but I don't feel like shelling out $300 per side, so a $30 sheet of 18g and a couple hours of fab time are the answer to this dilemma. I used the stomp sheer to cut 4ftx4in pieces, then bent a 1" flange to match the template I made.

https://farm5.staticflickr.com/4754/...ffb1b8ac_k.jpgIMG_20180301_142411311 by Ryan Mazingo, on Flickr

Once I got home I threw one in the shrinker and worked it until the curve matched the existing rocker. This was a surprisingly simple fab job, but it really couldn't have been done without the shrinker/stretcher. I bought the Harbor Freight cheapo version of this tool set last year, and I have yet to be disappointed with it for my purposes.

https://farm5.staticflickr.com/4657/...3f45927c_k.jpgIMG_20180301_145003834 by Ryan Mazingo, on Flickr

Once I had the curve right I Cleco'd it to the remaining rocker material and trimmed the excess material. Somewhere in there I cut out the bad stuff and prepped the interior surfaces. Overall very happy with how it's fitting, and it seems to flow well with the doors in place. Hopefully I'll get it welded on tomorrow, still have to get that small piece made under the front door, too.

https://farm5.staticflickr.com/4701/...fe9abbe8_k.jpgIMG_20180301_165626526 by Ryan Mazingo, on Flickr

Your making really steady progress, thanks for all the pics! I like watching people making panels vs buying them, although with my metal working skills it safer to buy them. It's always amazing how much rust is found in a rust free car :CRY:

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Originally Posted by 53 Chevy5

Your making really steady progress, thanks for all the pics! I like watching people making panels vs buying them, although with my metal working skills it safer to buy them. It's always amazing how much rust is found in a rust free car :CRY:

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Honestly, I don't have the skills either. I just live by the "fake it till you make it" mantra. I know I CAN do it, just not real sure HOW to do it. No reason not to try, though: it's only money, right? Lol. I've screwed up many a panel trying to figure this stuff out, so don't let the pictures fool you: I have no idea what I'm doing most of the time.

Lol, it sounds like we are alot alike.

Didn't get the outer welded on today, unfortunately. Decided I better just go ahead and replace the inner rocker, too. Probably could have just patched the little bit that needed fixing, but where's the fun in that? The flange was pretty thin, I doubt I could have welded anything to it without blowing through. I like new metal anyhow.........

https://farm5.staticflickr.com/4792/...281e6cda_k.jpgIMG_20180302_171203077 by Ryan Mazingo, on Flickr

Did you make them also? I'm going to a Harbor Freight store tomorrow night might check out some of their metal working tools.

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Originally Posted by 53 Chevy5

Did you make them also? I'm going to a Harbor Freight store tomorrow night might check out some of their metal working tools.

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I "repurposed" one of the outer pieces I made yesterday, just tipped the flange a little farther to a full 90°. I bent four 4' pieces, not knowing what length I actually needed, so I figured I could make good use of the extras.

Harbor Freight is great for the less complicated tools. I don't buy anything electrical from there, I just don't trust Chicago Electric, but the stuff that functions on simple principles is generally acceptable quality for the home shop. I have their English wheel, bead roller, shrinker/stretcher and a few other things. Oh, and the compressor pump too. I usually buy mass quantities of cutoff wheels too, whenever I'm in there.

Your right, I've learned what to stay away from in that store, here is a list I've put together on things not to buy !

Top 10 things you shouldn't buy from Harbor Freight
1) Parachutes
2) Fire Extinguishers
3) Pacemakers
4) Vaccines
5) Condoms
6) Scuba gear
7) Bullet proof vests
8) small nuclear reactors
9) Athletic cups
10) Boomerang

only thing worth carrying out the front door is the cash register .

Was able to get the rocker fully installed today. As you can see, I lap welded it to the remaining portion of the original rocker. I'm aware that this isn't the right way to do it, but after considering the options, I decided that this route will work just fine for me. To keep from distorting the panel I spread my tacks about every 4" or so, work from one end of the panel to the other and go back and do it again beside the previous tacks. Once I had about an inch or less of tacks stacked up, I pulled out the die grinder and knocked the welds about 90% of the way down: not trying to dress the welds at this point, just makes it easier to control the heat build up later on. Less heat means fewer warped spots in the finished product.

https://farm5.staticflickr.com/4699/...32d33b1e_k.jpgIMG_20180304_153431285 by Ryan Mazingo, on Flickr

With the top fully welded in place and all the tacks knocked down most of the way I started dressing the welds. Not quite perfect here, but it's much better than when I started. When dressing welds, resist the urge to tip the grinder at an angle, and constantly move across the length of the weld. Keeping the grinder flat against the surface ensures you're only removing the high spots and not digging scars into the panel that will require filler later on.

https://farm5.staticflickr.com/4776/...fa917b05_k.jpgIMG_20180304_170213386 by Ryan Mazingo, on Flickr

I also filled all the Cleco holes and ground them smooth. I also resisted the urge to make the front piece that's missing. I'll be much happier with the results if I bend the flange on the same break as I used to make the main panel, otherwise the radius of the bends might not match exactly. Simple realizations, like this, can save your work from looking like you don't know what you're doing, even if you really don't know what you're doing.

https://farm5.staticflickr.com/4668/...5ac31312_k.jpgIMG_20180304_170150805 by Ryan Mazingo, on Flickr

Finished up the rocker today. Made a small piece to fit the gap at the front, sorry no pics of the patch, lost my phone for about an hour.

https://farm5.staticflickr.com/4782/...e791abe9_k.jpgIMG_20180306_172328216 by Ryan Mazingo, on Flickr

You can see how well the two pieces fit together from this angle. Still have to weld the bottoms together and make the inner piece, but I plan to wait to finish that when I pull the body off the frame.

https://farm5.staticflickr.com/4609/...43c15725_k.jpgIMG_20180306_172320874 by Ryan Mazingo, on Flickr

Also did a little work on the rear quarter, where all this rocker business got started. I decided to split the patch I made before, because I wasn't able to form it with the correct radius to match the rest of the fenderwell without splitting it. No matter, I've got a welder to put it back together.

https://farm5.staticflickr.com/4710/...d84eee18_k.jpgIMG_20180306_174707383 by Ryan Mazingo, on Flickr

https://farm5.staticflickr.com/4784/...215056f5_k.jpgIMG_20180306_174703508 by Ryan Mazingo, on Flickr

Your doing awesome at making patches !

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Originally Posted by 53 Chevy5

Your doing awesome at making patches !

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I appreciate the compliment. After about 13 years of fiddling with this stuff, I finally feel like I'm getting it figured out. Having the right tools for the job is definitely helping me to work on it until I get it right. The only good part of aging, in my humble opinion, is that I just continue to aquire more tools. It's far too easy to get frustrated and settle for less than perfect when you just keep making things worse while trying to fix them. A lot can be accomplished in a short period of time with the right tools.

Back to the rear quarter today. Didn't really have a plan, just shooting from the hip trying to figure it out as I went.

https://farm5.staticflickr.com/4789/...9acfd30e_k.jpgIMG_20180310_141957693 by Ryan Mazingo, on Flickr

https://farm5.staticflickr.com/4774/...385ea719_z.jpgIMG_20180310_142027283 by Ryan Mazingo, on Flickr

https://farm5.staticflickr.com/4777/...59b8f9f8_k.jpgIMG_20180310_153245719 by Ryan Mazingo, on Flickr

https://farm5.staticflickr.com/4797/...47378e74_k.jpgIMG_20180310_154424712 by Ryan Mazingo, on Flickr

https://farm5.staticflickr.com/4783/...da7bf33a_k.jpgIMG_20180310_154530270 by Ryan Mazingo, on Flickr

It needs some adjustments, as I couldn't really work on it with the fender and door in place for reference, but it's a good start.

Looks like a very good start.