Thread: '38 Ford deck lid vs 37 Ford deck lid

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Originally Posted by Jack F

randyr,

Is there enough access to the backside of the welds to press some copper up against the weld? It would help to keep from burning through. The copper back up also makes it easier to fill the burn throughs.

Jack.

Thanks, Jack. Yes, since I have the outer skin separated from the inner framework, there is plenty of room for a copper plate. I have used this method before and it definitely helps dissipate the heat and doesn't stick to the metal. I'll give it a shot on some of the lesser pitted areas and see if I can weld up a few of the holes before resorting to an excessive amount of patch pieces.

Ok, I got to spend a little bit of time in the garage today and it was a little more encouraging.

I started by clamping a piece of copper under the lid and welding up a few rust holes.
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Then started making a cardboard pattern to replace that rusty corner on the lower right side.
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Flipped the lid over and did some more fitting...
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After it started to look ok, I took the plunge and whacked off the corner and clamped the new piece in place.
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I still have some more welding and grinding to finish up but my neighbor was tired of hearing the grinder
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Good stuff there Randy! Knew you could do it!

No really. Good job!

Randy you got started , I wonder how a shrinking disc would help on the marks on the second lid may eliminate them all giving you some good sheet metal patches .

Originally Posted by bluestang67

Randy you got started , I wonder how a shrinking disc would help on the marks on the second lid may eliminate them all giving you some good sheet metal patches .

Hmmmm.....not sure I understand what you mean, Bobby. Which lid are you suggesting I use the shrinking disc on?
The lower section of both lids is kinda the problem. On my original lid, my dad welded the inner structure to the outer skin in such a way that makes it kinda impossible to remove. That's what created all those waves on it.

After removing the skim coat of bondo on the new lid, I discovered all those dents, which I have managed to straighten quite a bit. Some more hammer & dolly work will make it much better. I'll probably still need a skim coat but it will be way thinner than it was.
Once I finish patching the rusty lower corners, I should be able to finish it out to look pretty good. That's what I'm hoping for anyway! Once I get the lid repaired, I'll concentrate on the lower pan and make it fit the lid properly.

Here are some pics of the nasty corner I cut off the lower right side. The left one isn't quite this bad but it will still need some attention.
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I think I successfully welded up several small holes across the lower section here. Once I get them ground smooth I know for sure.
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Originally Posted by randyr

Hmmmm..... I'll probably still need a skim coat but it will be way thinner than it was. Once I finish patching the rusty lower corners, I should be able to finish it out to look pretty good. The left one isn't quite this bad but it will still need some attention.

The above is good news! And good progress for sure.
Can I ask what you used to make the cut?

Originally Posted by 34_40

The above is good news! And good progress for sure.
Can I ask what you used to make the cut?

I bit it off with my teeth, Mike!! Actually, I used a 4" angle grinder with a cut off disc. For more intricate cuts I often use my Dremel tool with a 1" cutting disc. The Dremel discs are pretty pricey and don't last very long when cutting sheet metal, though

For cutting the new patch, I made the initial cuts with an electric metal shearer. I made the edge bends using a piece of angle iron in my vise and formed the right curves with light hammering on a gently curved dolly.... Yeah, you can go to town with that one! I did some additional trimming with a pair of snips.

Originally Posted by randyr

I bit it off with my teeth, Mike!! Actually, I used a 4" angle grinder with a cut off disc. For more intricate cuts I often use my Dremel tool with a 1" cutting disc. The Dremel discs are pretty pricey and don't last very long when cutting sheet metal, though

For cutting the new patch, I made the initial cuts with an electric metal shearer. I made the edge bends using a piece of angle iron in my vise and formed the right curves with light hammering on a gently curved dolly.... Yeah, you can go to town with that one! I did some additional trimming with a pair of snips.

Dang! a bit snippy today!
I would never harrass someone who bites through sheet metal with their teeth!
Especially when their playin' with the dollys

Originally Posted by 34_40

Dang! a bit snippy today!
I would never harrass someone who bites through sheet metal with their teeth!
Especially when their playin' with the dollys

I THINK I will stay away from that one.

+++++++++++++++++++++++++++++

Randy I thought the bottom of the lid you bought was a rotted out . That one looks really good . The shrinking disc I mentioned , if it would work on those long marks in the top . Never used one but from what I seen on You Tube they seem great .

Originally Posted by bluestang67

Randy I thought the bottom of the lid you bought was a rotted out . That one looks really good . The shrinking disc I mentioned , if it would work on those long marks in the top . Never used one but from what I seen on You Tube they seem great .

It was rotted on the corners, as you can see in the pics. The inner structure has a little rot but also repairable. Will check out the shrinking discs on youtube. Thanks!!

Today, I replaced the other lower corner. I still have some repairs to make on the inner framework before I shoot them with epoxy and reassemble.


Here I already formed the new piece and cut off the old. Now clamped together for welding.
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Looks really bumpy and twisted in this pic but it's not. The lighting is just playing tricks to make me look bad.
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Really nice patch, Randy! Going to have that skin looking great in short order!

2nd on Dave's statement , Randy a inspiration to us all who have sheet metal to patch . I went to garage today but as usual ended up picking up . I did how aver hang a lot of the 37 parts up to get them out of the way .

Originally Posted by bluestang67

2nd on Dave's statement , Randy a inspiration to us all who have sheet metal to patch . I went to garage today but as usual ended up picking up . I did how aver hang a lot of the 37 parts up to get them out of the way .

Thanks Bobby! and Dave! I still have tons to learn about this stuff but it's kinda fun when you cut out a bad piece and weld in a new piece that you made with some simple tools and it doesn't look too bad. We'll see how straight I can get the rest of the lid with a hammer & dolly and various other creative solutions. Will keep you guys posted...
I have some ideas brewing on my tail pan but gotta get this deck lid finished first.