Hey to everybody !
I started this thread beside daminc-s project (http://"http://www.foxtbirdcougarforums.com/showthread.php?t=17304") because sometimes I need Your advice or help and same time to show You what I have done :)
My overview is not so thorough as daminc-s, but at least something :)
At first I am sorry if my english grammar is not correct. It is not my native language and frequently I use dictionary.
Here is my project Cougar LS 1986 V6 3,8ltr.
I started it already a year ago. Project progress is very slow, because I dont have much time for it. My working schedule enables working with my project only two weeks in month. During those duty free weeks also the family and other thousands things demainds time also.
In last summer I started disassemble of car, then I built car body rotisserie and then new room for car and oops!!, summer was ended :(
My garage dont have heating and in winter I did inside room works. I rebuilded engine and transmission.
(http://img170.imageshack.us/img170/7002/motor046zl5.jpg)
In this spring.
(http://img410.imageshack.us/img410/823/keretood002fz1.jpg)
During disassembling I understood that car needs much more body work then I hoped :mad:
Some samples:
Floor (seems on pictures better then in reallity)
(http://img410.imageshack.us/img410/9427/cougsisu023yw2.jpg)
(http://img410.imageshack.us/img410/5555/cougsisu024gy4.jpg)
Fuel tank supporting
(http://img410.imageshack.us/img410/3527/pic007qh1.jpg)
Driver side rocker panel
(http://img410.imageshack.us/img410/4118/cougsisu013se4.jpg)
Wheel well openings
(http://img410.imageshack.us/img410/2392/keretood005xz0.jpg)
(http://img410.imageshack.us/img410/3774/keretood004xz3.jpg)
Lower parts of rear fenders. Both sides.
(http://img410.imageshack.us/img410/7647/keretood034qr9.jpg)
Air suction of heater-conditioner blower
(http://img410.imageshack.us/img410/8589/keretood042jk7.jpg)
Rear subframes
(http://img410.imageshack.us/img410/8273/keretood009cy7.jpg)
And hundreds little places more :) :(
So, for using body rotisserie, I must at first repair boby framework.
Here I repaired part of left rear subframe.
To get better access I removed rear panel.
(http://img262.imageshack.us/img262/8250/keretood014nb7.jpg)
Some pictures about repairing.
(http://img410.imageshack.us/img410/8752/keretood017rp7.jpg)
(http://img262.imageshack.us/img262/5954/keretood018gu6.jpg)
(http://img262.imageshack.us/img262/674/keretood023vv6.jpg)
(http://img410.imageshack.us/img410/4527/keretood027mk2.jpg)
(http://img410.imageshack.us/img410/895/keretood029mq6.jpg)
(http://img410.imageshack.us/img410/1720/keretood052ui2.jpg)
After removing all floor isolation (pitch?) mats, I found a lot of work is waiting me :mad:
Left side trunk and subframe
(http://img410.imageshack.us/img410/1294/keretood050sw7.jpg)
(http://img410.imageshack.us/img410/6947/keretood054mc9.jpg)
Same story on right side plus trunk bottom.
(http://img410.imageshack.us/img410/2016/keretood051wt9.jpg)
Floor under rear passengers.
(http://img262.imageshack.us/img262/7900/keretood058kj8.jpg)
(http://img262.imageshack.us/img262/1701/keretood059nq7.jpg)
(http://img262.imageshack.us/img262/3010/keretood061fc8.jpg)
(http://img262.imageshack.us/img262/1701/keretood059nq7.jpg)
(http://img262.imageshack.us/img262/1701/keretood059nq7.jpg)
Now the body is almost empty. Glasses, steering and so on are removed, except front and rear suspension components and crossmembers, brake calipers, lines and hoses.
For example about progress slow. I expend 3 hours to remove 2 (from 4) rear seatbelts fixing bolts.
One week I wet every day the bolts and trying lose them. Nothing. Then heating and beating, heating and beating again and again.
Result here:
(http://img262.imageshack.us/img262/1310/keretood067xp0.jpg)
(http://img262.imageshack.us/img262/5612/keretood069ma3.jpg)
Now my questions starts :)
About rear left subframe. Inside are two connections (another is hidden on pic) between subframe walls, it also going on bottom of frame and it has two nuts connected to nowhere. It is like double frame inside.
For what is it ?? At first I thought that it is for strengthing frame. But this "inside frame" was welded to "main frame" only with some buttweldings and was removed rather easely. Must I restore this "inside frame" or not ???
(http://img410.imageshack.us/img410/2526/keretood057bm2.jpg)
looks like it is put there to keep the frame from being crushed when a bolt goes through the frame for something. May have been a future use idea.
If there's no bolt going through it there, and if there never will be a bolt over there, I would be safe to say, not needed
Nice progress and frame repair.
I am SO glad we don't have to worry about rust here in Oklahoma.
Yeahh!! Happy people !! :) :)
Now summary what I did so far?
Repairing middle part of left rear frame.
But at first how my car is looking at the moment.
One day, when I cleared my garage, I showed little bit sunshine to my cat :)
(http://img146.imageshack.us/img146/4764/keretood086eu8.jpg)
(http://img146.imageshack.us/img146/1356/keretood087sy0.jpg)
For rust removing I use sandblaster and here is my temporary chamber.
(http://img146.imageshack.us/img146/9998/keretood091gx6.jpg)
Sandbalsted and coated with rust inhibitor (50% dilution of orthophosphoric acid).
Btw, white color shows that I made dilution too strong and it musted be moisted with water again or brushed away. I knew that I will do cutting and welding works and will be brush it away anyway. So I left it like it was.
(http://img146.imageshack.us/img146/889/keretood093te5.jpg)
Making curves and grinding off excessive weldings.
(http://img146.imageshack.us/img146/6986/keretood095lj8.jpg)
(http://img146.imageshack.us/img146/8389/keretood096zr6.jpg)
(http://img146.imageshack.us/img146/4391/keretood098br9.jpg)
Then piece by piece moved forward
(http://img146.imageshack.us/img146/5527/keretood099mx0.jpg)
(http://img146.imageshack.us/img146/6815/keretood100pu0.jpg)
(http://img146.imageshack.us/img146/3505/keretood104qk6.jpg)
Welded from both sides.
(http://img146.imageshack.us/img146/685/keretood105zd9.jpg)
From outside excessive weldings grinded off. Only for good looking. Maybe somebody will be see it :) And for my peace of mind :) Then temporary painted with zinc spray.
(http://img146.imageshack.us/img146/8575/keretood108yt7.jpg)
Inside painted with 2K primer.
(http://img146.imageshack.us/img146/9048/keretood109lf4.jpg)
Later I plan paint inside of frames with 2K paint for painting boats and ships underwater section.
WOW
You win, LOL
I believe the "Project Evolution" title should rightfully belong to you. :bowdown:
Did you find thinner wire for your welder?
Goodness! We some dedicated mofookie's on this board... I was thinking the other day that all that work work be crazy to perform... however, I then realized that I love my car a lot, so I'm guessing I would do the same thing if rust started to form.
Yes I found it and big thanks to you for advice :) Before it really was my problem with welding thinner sheet. After some experiments with unnecessary sheets, I found correct welder machine settings for thinner and thicker sheet and those weldings of frames are made with 0,23" wire also :)
Amazing work....................that is somthing I would never have the patience for.
That wire is nice, you can weld as fast as you can pull it, with no burn through.
1/8 inch is a little tough with it because of the wire size, but if you zig-zag the weld, it works ok. just a little slower
I've actually used about 8 lbs of wire on the car already. LOL
This place never stops amazing me. It seems like all the time we're getting new members with either AMAZING rides.....or rides that the member is making INTO an amazing ride with a ton of work.
It's been beaten to death and we all feel it....but there is something to be said about these cars when this is what they drive their owners to do. :bowdown: :bowdown: :bowdown: :cougarsmily: :birdsmily:
Keep up the good work
I'll be waiting for the next batch of pics.
More pics will approximately after two weeks.
At present I am on duty on ship :(
Hello again :)
Little update.
During my last short vacation days I did with my car nothing, but I did something for it :)
I started build roll workbench for making various grooves into floor sheets with various profile and width and maybe even some bendings on edge of sheet.
My skills working with lathe are poor and I fail with five rolls and just wasted material and time. After all I made one and half set of rolls with one profile and I get opportunity to try whether my idea will work at all.
Idea is simple. I will use bench from my hydraulic press.
(http://img373.imageshack.us/img373/7856/pink001lp2.jpg)
For making different grooves with different blendings I will use different rolls in different positions.
With two rolls I make the basic groove into sheet.
(http://img373.imageshack.us/img373/2330/pink008be1.jpg)
and if a sheet will warped or I need grooves with blendings, then I use three rolls.
(http://img373.imageshack.us/img373/4073/pink009qt6.jpg)
Now putting a sheet between the rolls and adding little pressure with jack. Then moving sheet by hand forwards and backwards. Again little more pressure with jack and again forwards and backwards. And again and again. It will take a lot of time. Of course if you are strong, you may do it with only one pressure adding :) My bench is not also fixed to floor.
Also be very carefully with edges of sheets!! They are nastily sharp. I broke two pairs of gloves and my hands also.
Beginning process:
(http://img373.imageshack.us/img373/4094/pink024am2.jpg)
Ending process:
(http://img373.imageshack.us/img373/5277/pink025fh2.jpg)
After firsts experiments I may say that the idea works and results are here.
(http://img373.imageshack.us/img373/4830/pink018nq5.jpg)
The profile is not exactly same as original but at least acceptable.
(http://img373.imageshack.us/img373/2046/pink020ck5.jpg)
(http://img373.imageshack.us/img373/7822/pink023jn8.jpg)
(http://img373.imageshack.us/img373/4484/pink028df3.jpg)
Btw, using bolts and nuts on rollers shafts is temporary. There will be shafts from correct material. Also this rusted sheet I found only for experimentations.
Building and experimentation will be continued :)
Wow, very impressive indeed. You are very creative and more patient than me :hick:
Looking forward to future updates...
Nice job,
You may be able to attach a variable speed motor to one of the roller shafts.
It would take a lot of work, out of the work, so to speak.
A hand crank would also work, but I don't think you have the room for that.
Sorry about long-time silence in this thread.
I must confess, that nothing notable wasnt happened. Shame on me :)
The project is on standby.
I changed my "conception" about bending and processing of sheet metal.
However I decided to build a classic english wheel and use it also for sheet bending.
It have rubber and steel upper wheels.
(http://img393.imageshack.us/img393/8692/pink044xq9.jpg)
(http://img512.imageshack.us/img512/6127/pink049cc8.jpg)
Same system for bending, like with hydraulic press.
(http://img512.imageshack.us/img512/2552/pink042sj2.jpg)
Also I bought some books and dvd for learning.
(http://img512.imageshack.us/img512/7021/pink048ho8.jpg)
Now I training how to process sheet metal and same time I continue to making lower rolls with different profile for my english wheel.
In winter I cant work with my project often, because my garage have some weak heating only in one room. Another room is cold and there my car stands.
At least in spring I will continue working with my project more faster.
Hey! I was thinking about your car the other day! Great to hear from you again. :D
You MADE an english wheel. Wow. Not bad at all, definitely should be useful haha. Wish I had the patience to undertake an art like this...
Nice job on the wheels, That should help you out in a bunch of different ways.
I think I have that "Classic Car Bodywork" book. Or one very similar to it. Bought it when I was 16 or 17.
Good luck on the metal bending. I'm sure there's a lot of prefab work you can do for your car in the heated room.
Hello :)
Long time have been quiet here.
The "evolution" of the project has been very very slow. I still in "Stone Age" but daminc is very close to nowadays
During winter, in the heated room, I strengthen my English wheel frame but mostly there was a lot of work with lathe and here is the result:
my "Army of rollers" :)
(rollers are hardened)
(http://img204.imageshack.us/img204/9350/pink055.jpg)
(http://img204.imageshack.us/img204/2407/pink058.jpg)
Some tests
(http://img204.imageshack.us/img204/6639/pink067.jpg)
Also I made little sheet bending device and device for pressing grooves to the floor panels with my hydraulic press.
(http://img204.imageshack.us/img204/6162/pink064.jpg)
(http://img204.imageshack.us/img204/810/pink066.jpg)
Here is my first repair test. Curves formed by English wheel.
(http://img204.imageshack.us/img204/6468/kere09003.jpg)
(http://img204.imageshack.us/img204/166/kere09005.jpg)
(http://img204.imageshack.us/img204/9525/kere09008.jpg)
(http://img204.imageshack.us/img204/6060/kere09015.jpg)
Now, in summertime I hope accelerate "evolution" and make updates here more often.
Wow! You are a VERY talented fellow! I look forward to seeing what more you get done on your car! Keep up the wonderful work!
very nice work,keep the pics coming..................this stuff is insane.
Great work! I just found my old English wheel blueprints, and may start on building one myself. Hopefully by year's end.
That's incredible. I'd like to have an english wheel, but I'd like to know how to use one even more...
I can see a lot of money coming from your skills and that wheel.
Amazing work. Cant wait to see more.
That is so cool that you made all that to put your car together. I think you're now the master panel maker of the group, and I can't wait to see this years progress. You get the official bow down smilie my friend.
:bowdown: :bowdown: :bowdown: :bowdown:
I think what you two have done, and are doing with your cars is incredible...I'm not all too much envious of people...but the skills you both have makes me want to be able to do that as well.
On a somewhat different note, have either of you thought of making replacement panels to sell?
Thank you all very much ,for good words, your moral support and encourage me to continue :) :)
I myself wish, that I have skills to use my E-wheel correctly.
Making panels for sell.... oh no, loooong way to go. Not so much quality
All restoring progress is slow, I take this like a learning experience and I try to make the repairs invisible as possible.
This time I also tried to use flexible shape patterns for making correct pieces.
As you see, not much success. Pieces are not perfect but at least more or less acceptable.
(http://img195.imageshack.us/img195/226/kere09017.jpg)
(http://img195.imageshack.us/img195/2940/kere09019.jpg)
(http://img195.imageshack.us/img195/6384/kere09022.jpg)
(http://img195.imageshack.us/img195/484/kere09023.jpg)
(http://img195.imageshack.us/img195/1668/kere09024.jpg)
(http://img195.imageshack.us/img195/8725/kere09025.jpg)
(http://img195.imageshack.us/img195/4082/kere09026.jpg)
this piece is waiting about to make fuel tank supports
(http://img195.imageshack.us/img195/3140/kere09027.jpg)
fuel tank support are totally rusted and I even don´t know how originally are fixed to tank supports those metal stripes, which are under the tank :(
(http://img195.imageshack.us/img195/6061/kere09029.jpg)
(http://img195.imageshack.us/img195/1560/kere09035.jpg)
as compared to other pieces, this was easy to make
(http://img195.imageshack.us/img195/4173/kere09037.jpg)
My welding gas was ended and I used flux core wire for temporary tack weld.
I have also some questions.
I can´t remember, which part was fixed to bracket nr1 on picture? I cut it out. Must I restore it ?
If I remember correctly, then bracket nr2 is for fixing the spare wheel?
(http://img211.imageshack.us/img211/7070/kere09028copy.jpg)
my full size spare is attached to #1 with a threaded rod with a hook at the base.
I don't have the other bracket in my trunk. It might be for the jack.
Sorry, I forgot to measure the brackets.
I'll go out there now and get the measurements. Don't go anywhere
Your doing a great job with those panels
keep it up. These cars are worth saving.
here are the tank supports. I traced them on paper
I can send them in actual size if you send my your email address
I believe the bottom of the pass side is about 7 1/2" wide
They're both the same shape and size, but the pass bracket is extended to the very top of the trunk pan and is welded to the side of the frame. I couldn't weld the bracket to the side, so I modded it to weld to the bottom of the frame instead.
I also drilled out the corners with a 1/4" bit to let any water out.
I still need to put a bolt on them to fasten the tank straps. I may just drill a hole and weld a nut to the bottom of the bracket .
(http://i233.photobucket.com/albums/ee79/daminc/Tank%20and%20supports/img033.jpg)
(http://i233.photobucket.com/albums/ee79/daminc/Tank%20and%20supports/img032.jpg)
If you want specific sizes or pictures, let me know.
(http://i233.photobucket.com/albums/ee79/daminc/rear%20end/IMG_5015.jpg)
(http://i233.photobucket.com/albums/ee79/daminc/rear%20end/IMG_5017.jpg)
(http://i233.photobucket.com/albums/ee79/daminc/rear%20end/IMG_5018.jpg)
Amazing work by both of you guys!
Keep up the good work! You guys should go into business together! lol
Thanks Jerry :)
Now I have main measurements to make tank supports and I guess how tank straps are fixed to supports :)
About spare wheel.
I have small size type spare. Whether the rod with hook looks like this ?
(http://img193.imageshack.us/img193/4462/hookd.jpg)
Anyway, I would like to order from you some extra pictures for me :D when your tank is supported and how your spare wheel is fixed (when trunk is complete)
That's the hook.... If you have the round plate, and the large wing nut that went with it, then your all set.
When the trunk is complete, it all looks like this. but I'll eventually have some pics when it's done. the jack actually fits under the tire quite well.
(http://i233.photobucket.com/albums/ee79/daminc/cougar%20before/IMG_2841.jpg).
Don't worry, I'll send you pics of the tank and the new straps when it goes in.
here's the straps. if you can't buy them over there, I'll get you some measurements for them too.
(http://i233.photobucket.com/albums/ee79/daminc/new%20car%20parts/IMG_5055.jpg)