Thread: A new project for the firebird

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Rain yesterday, but tonight I spent an embarrassing amount of time forming the outer skin patch. I'm looking into a DIY metal brake. I've also got an idea that I haven't seen before: should I make dies for my log splitter, it would be a powerful press. I'll put some finishing touches on the outer patch and weld it in tomorrow.

That log splitter idea may work out well keep us posted

If you see the welding cables jump - it could be a weak connection on the ground clamp. Even brand new metals, they have a skin that is known as mill scale, you need to get through that to have a good connection. The scale can prevent a connection and forces the amps higher to get the electrons through...


But I'm sure you knew that. ( wink, wink)

Yes, I always try to clamp off on the part, and ground clean. Sometimes I get lazy and clamp off on the table. Especially if I'm moving it around instead of reaching in.



Anyway, today I beat the patch into submission. If you look close you'll see the patch is in two pieces and that was on purpose, but the seam isn't in the center of the bend as planned, but whatever. The next will be better, right?

All hubris aside, here is a shot of my welds. Not exactly sexy, but after they're ground smooth, no one will be the wiser. I got a little rushed, and the panel warped out slightly but there is lots of room to access with a dolly and planish it smoth.

This corner is nearly done. Just a couple more small pieces and I'll be doing driver side next. It should go easier.

Also I've figured out something on the pixels.
If I get an error message when I try to upload image, then it has gone through. I can post narrative use the "open new window..." button and it will propagate as last pic uploaded. Also, the software seems to rotate image 90* clockwise, so if I take the pic with phone rotates 90* CCW it posts correctly.

Isn't tecnoligy wonderful

Good job on the phone tech discovery!!

I'm no pro welder but it looks to me like you need to kick your heat up a notch or two. Your weld material is squatting on top of the metal with almost no heat signature to either side. I'd be interested in what the experienced guys, like maybe MP&C say? Perhaps I'm all wet, and your welds are PRIMO!

Primo they ain't. They do have penetration though. I ground it down, and fixed four pinholes, and finished with a 80 grit flap disc, looks good. Also, I've been meaning to hype this old can of clear enamel I'm using to coat the patches. The brand name is fixall, and it covers well and dries quick. There is some German spray paint at work which comes with the new machines for touch up which is also awesome. It is Frei Lack. (Translates to free paint - wierd)

Any tips are welcome. I ran the welder on power #2 for these welds. Setting #3 works a bit better for joining two stainless patches, but I'm hesitant to try it on the old steel.

The stainless patches are 18ga but I think the body is 20ga.

The patches are being butted without gaps, that may be part of the issue. I'll try to remember to leave a small gap, about a sixteenth.

I tried a test weld on some scraps pieces today. #4 is too high, melts out. #3 did fine, I put a gap about the width of the metal, just under a sixteenth. The gap is the key.

I started templating patches for driver side front quarter. It is much worse than the passenger side was. Fortunately I kept some key templates from the other side.

I've decided to pursue making dies for the log splitter. I started by making a contour profile gage. Next I'm taking some quarter inch plate and slicing it to profile with the plasma cutter, and using the grinder to get final shape.

I set the cutter to max power and air, and it cuts easy and quick but leaves a pile of slag on the parts.also, the curfew is a bit too much, I can't use the cut out for the other die half. That will have to be made separately.

I'll stack the die pieces and weld them together to form a single die. I'd like to get one about six inches width, since this profile will be used to shape the running boards, about 40" long.

But it seems to me, the gentleman with the Lennox only makes his about 2" wide, which is a much more reasonable goal given the effort necessary to shape the dies.

Once the dies are done, I'll have to figure out die holders which will mount to the log splitter, and allow me to change dies for various profiles.

Also on the agenda, to use the scrap metal I've scrounged from the dumpster at work, and convert one side of my weld table to a metal break. I'll need some of the 20mm cutter shaft and bearings which I'll scrounge tomorrow.

Somedays, baby steps are all we can do. Dumpster diving at work netted several lengths of 20mm shaft for the brake hinge and a custom dolly, maybe guide shaft for the hydraulic press dies. Eight pillow block bearings for the metal brake.

After work, I attended an emergency house committee meeting for post operations (VFW), lent my prowess with a chainsaw to the sheriff's department clearing a tree from the highway (I cut they cleared) and then fixed an electric pellet smoker for my very dear friend Jill. The auger was locked up because the pellets weren't run out: humidity down South, don't ya know. The second time for it, now maybe she'll listen and run out the darn pellets.

Baby steps.

Have I mentioned how nice it is to have a build log?

The last couple days i got busy making the dies for the log splitter. The first couple were finished with grinder, and I could see that was not going to give a favorable result. For the third and fourth I finished out with a half round bastard file. Way better. Takes longer. Time spent now will be repaid in spades later. Or something like that.

That's the press die pieces.

Originally Posted by firebird77clone

Have I mentioned how nice it is to have a build log? Or something like that. That's the press die pieces.

UMmm... no I don't think you did mention how nice it is!... Need to do it again! LOL

But the die pieces look really good! I think any way.

I'm looking forward to your report on the first use of the log splitter as a press! I'm thinking that when you constrain the ram your force is going to ramp up very quickly with only two options - 1) keep going or 2) reverse direction to relieve the force. Be safe.

Thanks spears, I expect to nibble down the length. I am deeply concerned that I will get severe warpage. Perhaps it would be prudent to get the sheet metal brake fabricobbled first, and pre - bend the profile , then use the dies to finish the shape?

This weekend my spare time generated greenbacks rather than progress. I lifted the box off a delivery truck, then changed all the mounting tabs to fit another. The lifting was sketchy, nearly dropped if off at the end. Got over confident, but all's well that ends well. Hopefully back on the Plymouth this weekend.