Ol' Rusty - FB/EK Sedan

[funkyscooter]

Been a while - still plugging away at the boot area. But got bored and then sidetracked by a 3D printer. Got 2 speed wiper kit and was underwelmed with the wiper switch knob. Not very period correct so I thought I'd have a crack at replicating a knob from the light switch.

Using free version of Sketch Up which is pretty basic, but managed to make this.

Screen Shot 2023-04-21 at 9.03.46 am.png (380.49 KiB) Viewed 702 times

Then after 1 aborted attempt I printed this. Took about 30min. It printed with PLA which won't withstand high temps but good enough for prototyping.

IMG_1564.jpeg (598.42 KiB) Viewed 702 times

Resolution is to about 0.4mm. Needs some clean up. So used the failed one as a test - sanding it in the drill press. 120/180/240 grit. This was at 120.

IMG_1565.jpeg (783.84 KiB) Viewed 702 times

Then attacked the proper one. This was after sanding and a trip to the sandblaster. Its pretty smooth. If I do this I'll probably print in ABS which you can use chemical vapors to melt the outer surface of the print for a better finish.

IMG_1566.jpeg (671.84 KiB) Viewed 702 times

This is the end result. Not a prefect match - need to learn better modeling software. But that == $$$$$. So happy with the free version.

IMG_1570.jpeg (464.48 KiB) Viewed 702 times

Then I searched the shed and found the wiper switch. What a goose! I had a knob stashed away from my first FB holden that I found at Christmas and put on the switch - then erased it from my memory.

IMG_1568.jpeg (624.75 KiB) Viewed 702 times

Not a total waste - going to make a bunch of these (or similar) to add some switches to my (well off in the future) centre console design.

[funkyscooter]

Found a scrap of stainless and a ball bearing - pressed this out. It's too high, need to recess the top of the knob. But it's an idea.

IMG_1571.jpg (609.96 KiB) Viewed 688 times

[Errol62]

Clever work scotty. I've been wondering myself about the knob, as I have a kit as well.

Sent from my SM-G781B using Tapatalk

[In the Shed]

That’s creative Scott and is a great copy of the original. I reckon these could be cast with a two part resin as another option.

Maybe the next trial is to print a FB bonnet bar?

Regards
Stephen

[Blacky]

The switch I used will accept a stock wiper knob.

[funkyscooter]

That’s creative Scott and is a great copy of the original. I reckon these could be cast with a two part resin as another option.

Maybe the next trial is to print a FB bonnet bar?

Regards
Stephen

Think you're right Stephen - casting would be the best option for strength and detail (assuming you have the knob to cast). Might have a crack at that one day. Another option would be a resin printer which is much better for small objects and fine detail.

I'd have a go at a bonnet bar - but the volume needed for the printer would be huge. As it is , the one I brought for my son for Uni is approx 400x400x400 which is pretty big for a sub $1000 printer. Should have read more - at that size it can take up to 28 days to print. Total overkill.

Was a fun exercise - now back to metal

[funkyscooter]

Did the following about a month ago. Got a bit of down time so thought I'd write it up.
Working on the rear passenger corner window, just above where I replaced the boot lid rubber lip on page 31. It's been fixed in the past, lots of brazing. New holes have appeared and at first I had a go at cleaning out the rust with a die grinder and filling with weld. Looks rough as and spent a lot of time grinding already thin metal.
Not happy, and there is rust between the boot hinge and the rear window 'frame'. Lots of head scratching until finally I decided to cut it all out and start again.
So I braced it up with some old metal rod from a Christmas tree and started cutting.

IMG_1216.jpeg (950.83 KiB) Viewed 608 times

Inspected the metal sandwich around the window frame and looks like its only this section that needs replacing here.

IMG_1217.jpeg (1.08 MiB) Viewed 608 times

Scrap bin provided a replacement.

IMG_1218.jpeg (857.47 KiB) Viewed 608 times

Not much of profile on this piece - just a light hand bend.

IMG_1219.jpeg (824.79 KiB) Viewed 608 times

Welded in and tidied up

IMG_1228.jpeg (1.03 MiB) Viewed 608 times

[funkyscooter]

Next - remake the missing window frame piece. This is made out of 1.2mm. Gave the shrinker/stretcher a bit of a work out. Not an easy profile as it curves in 2 directions and the curve is more pronounced to the left hand side. Many trips between car and shrinker/stretcher later.

IMG_1230.jpeg (554.36 KiB) Viewed 607 times

IMG_1232.jpeg (697.96 KiB) Viewed 607 times

IMG_1233.jpeg (789.41 KiB) Viewed 607 times

Then on to replacing the lower gutter. Has an almost 90 degree profile. Made up a jig with some flat bar strips welded to more flat bar that all bolted together to sandwich some metal.
This was my test piece.

IMG_1234.jpeg (629.3 KiB) Viewed 607 times

The step isn't quite aggressive enough, but despite this I thought I could still use it, and went ahead and shrunk the top side whilst stretching the bottom side to get the profile. A couple hours later, getting close, over correcting, etc. and I had this.

IMG_1237.jpeg (1.06 MiB) Viewed 607 times

So being a test piece - it's too short and needs to be remade. Also need to deal with the areas I cut out over the outer lip. The other problem is the window frame replacement - I intended on rolling the edge over to maintain the factory appearance. Not wide enough for that so it will go on as is.
Over it.

[funkyscooter]

Days pass, mentally reset.
So added the missing lips.

IMG_1239.jpeg (714.36 KiB) Viewed 606 times

Remade the gutter, tried to get the profile a little more aggressive (if I had room I would have got a bead roller and done it properly), and many trips between work bench and car got me this.

IMG_1308.jpeg (724.45 KiB) Viewed 606 times

Tacked

IMG_1309.jpeg (906.41 KiB) Viewed 606 times

Welded

IMG_1313.jpeg (1011.71 KiB) Viewed 606 times

Happy with the penetration

IMG_1312.jpeg (943.81 KiB) Viewed 606 times

Add frame, grind some more and finally get to this.

IMG_1316.jpeg (994.23 KiB) Viewed 606 times

[Blacky]

I admire your tenacity mate - no way I would have the patience to do that .......

[funkyscooter]

Finally, got some more time this week and spent another day doing more of the same a bit further along the gutter.
This bit near the centre will require the removal of the brace underneath.

IMG_1575.jpeg (860.39 KiB) Viewed 600 times

IMG_1576.jpeg (600.22 KiB) Viewed 600 times

Wire wheel it so I can easily see the spots. Removed with spot weld drill. Still not convinced by the spot weld drill. Seems to require a lot of force for not much gain. If I know I am going to replace either piece I just drill it out.

IMG_1577.jpeg (768.65 KiB) Viewed 600 times

Started by removing the brazed section at the end of the last section. Would have done it before, but the piece was already getting too long, and when I originally looked at this, it seems to be rust free. But hey, I'm here and never will be again so might as well do it too.

IMG_1578.jpeg (987.47 KiB) Viewed 600 times

IMG_1580.jpeg (872.59 KiB) Viewed 600 times

Then on to the bit in the centre.

IMG_1581.jpeg (1020.56 KiB) Viewed 600 times

Welded the bit closest to the inner lip from underneath (well sort of sideways standing where the fuel tank used to be), and the rest from up top. Ran out of time, will clean up, do the boot lid lip, and replace the brace on the weekend.

IMG_1585.jpeg (945.94 KiB) Viewed 600 times

[Errol62]

Brilliant!

Sent from my SM-G781B using Tapatalk

[funkyscooter]

I admire your tenacity mate - no way I would have the patience to do that .......

What, weld, or write it up! Feels like it takes longer to post this stuff than it does to do it
Is it weird to say I'm going to miss it when its done. Its oddly satisfying. And it delays all the jobs I have to do that I have no clue how I am going to do!

[Brett027]

Neat work on that weld Scott. Looking through your work while floating somewhere between London and Singapore. Technology is grand

[Blacky]

Neat work on that weld Scott. Looking through your work while floating somewhere between London and Singapore. Technology is grand

Giving you the urge to start another one is it ????