Author |
Message |
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
Posted: Tue Jan 16, 2024 6:35 pm Post subject: Re: 59 Karmann Kab |
|
|
First order of business today was to take care of all the small rusted ares on the inner panels so we can start welding on the exterior skins. I got the the skins coated with some weld through primer so there is no raw metal being trapped. I also located and drilled the holes in the rocker skin in order to be able to attach it to the convertible inner rocker support panel. We also got the inside rear rocker panels all closed in. Once all that was done my son went onto the exterior skins staring with the lower front fender. While he was doing that I filled in a large amount of cancer spots and drilled holes in the nose skin , nostrils and headlight buckets. When I finished that I went back onto fishing up all the details on the rear lower fender panel.
_________________ ⚒ Believe In The Power Of Positive Thinking ⚒
Purpose Over Pleasure 🕊
“Hard Werk ⚒ God First
https://music.youtube.com/watch?v=_aoE5aYSutY&si=mkZKPxd_41QA1kfs
https://music.youtube.com/watch?v=_NzUyyVexAE&feature=share
https://music.youtube.com/watch?v=UI8yUrIWS7E&feature=share |
|
Back to top |
|
|
TRS63 Samba Member
Joined: December 17, 2017 Posts: 1012 Location: Stuttgart - Germany
|
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
Posted: Wed Jan 17, 2024 6:34 pm Post subject: Re: 59 Karmann Kab |
|
|
We got the lower fender repair all wrapped and moved onto tacking up the rocker skin and rear fender panel
I needed to get creative to remove the sag in the door sill first and then I was good to go. Once I final fit the rocker skin and tacked it place I moved onto final fit and tack of the rear fender panel. My Son is only part time and works just a couple or few days a week and with have found a good rhythm where I make the parts , fit and tack them in place and he comes along and welds and metal finishes them. So once my duty was done I moved onto the lower front firewall area. I whipped up a quick and dirty hammer form and it was off to the races. 😜👊
_________________ ⚒ Believe In The Power Of Positive Thinking ⚒
Purpose Over Pleasure 🕊
“Hard Werk ⚒ God First
https://music.youtube.com/watch?v=_aoE5aYSutY&si=mkZKPxd_41QA1kfs
https://music.youtube.com/watch?v=_NzUyyVexAE&feature=share
https://music.youtube.com/watch?v=UI8yUrIWS7E&feature=share |
|
Back to top |
|
|
metz Samba Member
Joined: March 31, 2005 Posts: 280 Location: Norway
|
Posted: Thu Jan 18, 2024 12:22 am Post subject: Re: 59 Karmann Kab |
|
|
Digging these photo dumps. Great work! _________________ 68 panel
64 ghia coupe |
|
Back to top |
|
|
calexican Samba Member
Joined: June 11, 2008 Posts: 731 Location: El Paso, TX
|
Posted: Thu Jan 18, 2024 8:24 am Post subject: Re: 59 Karmann Kab |
|
|
What a beautiful legacy. I have to say your photos are really great. I can’t seem to get enough of seeing the anatomy of these beautifully designed cars, and the way you include some of the other cars in the shop, the Porsche….you can see the lineage….so cool….maybe someday for me, I’ve been dreaming about it for over a decade… keep up the good work! |
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
Loren Samba Member
Joined: January 10, 2004 Posts: 1707
|
Posted: Thu Jan 18, 2024 1:51 pm Post subject: Re: 59 Karmann Kab |
|
|
Wish my Ghia cab had been as nice as this one to start with. You will have this knocked out in no time. |
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
sputnick60 Samba Moderator
Joined: July 22, 2007 Posts: 3929 Location: In Molinya Orbit
|
Posted: Fri Jan 19, 2024 1:46 am Post subject: Re: 59 Karmann Kab |
|
|
WrennMetallWerks wrote: |
I had given it some thought and realized some folks maybe interested in the explanations of the metal shaping process I’m posting pix of? I would be happy to take the time to freely give the knowledge that was so generously passed on to me from my metal mentors. ⚒☑️👀🕊🤍 |
Yes. Of course we'd be interested. Please do
Nicholas _________________ '66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
|
Back to top |
|
|
VeloMikey Samba Member
Joined: March 19, 2012 Posts: 664 Location: So Cal
|
Posted: Fri Jan 19, 2024 7:17 am Post subject: Re: 59 Karmann Kab |
|
|
I will start...
What is "metal finishing"?
Is the green tape thing a pattern? Why isn't it made of cardboard or metal?
Why are there what look like relief marks on the pattern but they are not cut out? _________________ '58 Ghia 2387cc with a Berg / Folts 5 Speed
Ghia Build Thread https://www.thesamba.com/vw/forum/viewtopic.php?t=768748 |
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
Posted: Fri Jan 19, 2024 8:32 pm Post subject: Re: 59 Karmann Kab |
|
|
Hey folks…. I was able to finalize the first stage of the metal finish and shaping on the lower rear quarter panel. Once I started to final fit it to the car I quickly realized how bad off the taillight opening and surrounding area was. I ended up cutting out the taillight housing mounting bracket to repair it and to get access to surrounding areas for correction. When trying to fit the taillight I discovered the body line was way off from a previous repair. At first I thought it was the top
hole that was off. I reshaped the body line and filed the body line back into its proper shape/position. There was a lot of hand dolly work around the entire area of the open to get it ready to accept the tailgate properly. Once I was happy with all that is was able to final fit and tack in the lower fender panel. I got it fitting real well and tacked into its final resting place. That’s a wrap for this rotation. 🤩👊
_________________ ⚒ Believe In The Power Of Positive Thinking ⚒
Purpose Over Pleasure 🕊
“Hard Werk ⚒ God First
https://music.youtube.com/watch?v=_aoE5aYSutY&si=mkZKPxd_41QA1kfs
https://music.youtube.com/watch?v=_NzUyyVexAE&feature=share
https://music.youtube.com/watch?v=UI8yUrIWS7E&feature=share |
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
Posted: Fri Jan 19, 2024 10:04 pm Post subject: Re: 59 Karmann Kab |
|
|
VeloMikey wrote: |
I will start...
What is "metal finishing"?
Is the green tape thing a pattern? Why isn't it made of cardboard or metal?
Why are there what look like relief marks on the pattern but they are not cut out? |
Hey Mr Mike. I love everything about the way you approached this. To me
this is what the forums are all bout. All of us sharing, learning , and engaging.
I will be looking for folks to reach out the way you did and ask about things that interest them. Thanks for that Mr Mike , very cool. Great questions to by the way.
So metal finishing has many forms….
Particularly in this situation it was the final steps after the panel is welded in and it started with grinding the welds down about 80 percent using the edge of a small cutting blade once that was done I use 2” 36 grit roloc disc on and angle sander to take the welds as flush as I can get them without taking away metal on the surrounding metals that I just joined together. After that I switch to a 3” 60 grit roloc disc to lightly blend the welds and the materials, being very careful to take off very little more metal then necessary. Once that’s done I add lay out ink to the panel to use as a guide coat and then using a vixen file I file the panels and what litt is left of the welds to just about as level as it can bel, the lay out ink tells me where and if their are highs and lows that need to be addressed to reach the desired finish I’m after. I do what’s necessary to improve on the panel one last time if i feels it’s necessary , then the real “finish “ starts. I begin with a DA sander with 80 grit sand paper and then change to 100 grit once everything is blended to my satisfaction then I use another DA with a red Scotch Brite to get the final result you see in my photos. All of this takes quite some but I’m getting faster at every year.
Yes Mike , the green tape is a pattern. I made it about eight years ago , the reason it is tape is because if you use it in a certain way directly on a good panel it will keep the shape of said panel when removed . The trick is to do at least three layers in opposite directions. When this particular pattern was made it was made to shape a panel I needed for a project I had at the time. The relief cuts you see dictate where I will need to shrink the panel to get the shape I want. When the pattern of tape is done on the good panel I was trying to duplicate I pulled it off the car once I made the cuts it lays out flat so I could transfer it to metal.
Another popular way to do this is with butcher paper, when you fold the tucks of the paper to contour and the panel it tells you almost exactly where to shrink, the paper is a cheap and simple way to make a paper for metal shaping.
Great questions man. I appreciate the engagement 🤩👊 _________________ ⚒ Believe In The Power Of Positive Thinking ⚒
Purpose Over Pleasure 🕊
“Hard Werk ⚒ God First
https://music.youtube.com/watch?v=_aoE5aYSutY&si=mkZKPxd_41QA1kfs
https://music.youtube.com/watch?v=_NzUyyVexAE&feature=share
https://music.youtube.com/watch?v=UI8yUrIWS7E&feature=share |
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
TRS63 Samba Member
Joined: December 17, 2017 Posts: 1012 Location: Stuttgart - Germany
|
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
DariuszPlich Samba Member
Joined: July 06, 2017 Posts: 60 Location: Polska
|
Posted: Wed Jan 24, 2024 12:08 pm Post subject: Re: 59 Karmann Kab |
|
|
I see a professional approach and execution. Great, I'm waiting for more. Maybe someday I'll be able to do that too ) |
|
Back to top |
|
|
WrennMetallWerks Samba Member
Joined: December 06, 2007 Posts: 2709 Location: Rescue ca
|
|
Back to top |
|
|
|