Amazing work, thank you for posting. I will be following the build.

Great work. You are a true craftsman. Thanks for sharing.


Jason

Monday, I was burning off the remnants of an old, brazed on, patch when I realized I had my lower door brace welded to a panel I had to replace...:rolleyes2:


https://www.yenko.net/forum/cache.ph...2FDSC08557.JPG


I cut another tube and moved it back and up on the vent panel.


https://www.yenko.net/forum/cache.ph...2FDSC08558.JPG


This is the replacement part.


https://www.yenko.net/forum/cache.ph...2FDSC08561.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08562.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08563.JPG


In the process of doing that, I was wire wheeling the area and found rust damage in the toe board and pillar. That was to be Tuesdays work.



https://www.yenko.net/forum/cache.ph...2FDSC08566.JPG


I cut the toe pan out and made a tag board template and then rough cut a piece of sheet steel.


https://www.yenko.net/forum/cache.ph...2FDSC08567.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08568.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08569.JPG


I then bent the weld flange and used the stretcher jaws to give the piece some curvature to match the floor.


https://www.yenko.net/forum/cache.ph...2FDSC08570.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08572.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08573.JPG


I didn't take any pics of the pillar patch, but here they are drill screwed in place for floor pan test fit.


https://www.yenko.net/forum/cache.ph...2FDSC08574.JPG

Today, I made the patch for the right side inner quarter structure. I wasn't completely happy with the way the left side fit and looked, so I made this one to fit inside the existing panel. Looks WAY better in there.

https://www.yenko.net/forum/cache.ph...2FDSC08575.JPG

On this side, I cut out the rotten wheel house so I could extend the patch far enough to cut and form to the new house.

https://www.yenko.net/forum/cache.ph...2FDSC08575.JPG

Here's a "stop" the owner screwed on 51 years ago to fill a large rust hole with bondo...:grin:

https://www.yenko.net/forum/cache.ph...2FDSC08577.JPG

Seems I forgot to take a pic of the bondo mountain under the stop.
New panel all formed and cut to fit.

https://www.yenko.net/forum/cache.ph...2FDSC08578.JPG

https://www.yenko.net/forum/cache.ph...2FDSC08579.JPG

Much better looking and easier to weld too.

https://www.yenko.net/forum/cache.ph...2FDSC08580.JPG

I liked how this fit and looked so well, I modified the left side to be the same.

https://www.yenko.net/forum/cache.ph...2FDSC08589.JPG

In getting ready to test fit the floor pan, I had to remove the weld flange remnant from the toe board. I don't like spot weld drills for this, as they partially cut into the panel I want to save. Using a grinding wheel is my preferred method of spot weld removal and then clean up the flange with a 80 grit disc.

https://www.yenko.net/forum/cache.ph...2FDSC08587.JPG

https://www.yenko.net/forum/cache.ph...2FDSC08588.JPG

Then I started mocking up the new wide wheel tubs. These are for a sedan, so I cut off the lower part that won't be used on the wagon.

https://www.yenko.net/forum/cache.ph...2FDSC08582.JPG

https://www.yenko.net/forum/cache.ph...2FDSC08583.JPG

I layed it in place, to get an idea of where I was going to go with this and it seems that it will be easier than I thought to graft this onto the wall. Cutting the cabin and cargo floors will be a challenge.

https://www.yenko.net/forum/cache.ph...2FDSC08584.JPG

https://www.yenko.net/forum/cache.ph...2FDSC08585.JPG

As well as getting the radius cut in the existing panels to fit the new house into the wall and blending it so it looks like to belongs there.

https://www.yenko.net/forum/cache.ph...2FDSC08586.JPG

Test fitting the cabin floor is about the next move, so I have to remove the rest of the old cabin floor at the cargo floor. There is a brace under this to reinforce the cabin floor, so I just drilled thru all 3 panels to remove the floor remnant and brace. Only got halfway thru when the time bell rang. I'll get this out and the floor layed in place next Monday. I think the car will take on a pretty cool appearance with a complete, new floor sitting place...:smile:


Thanks for tuning in for the fun and butchery.


https://www.yenko.net/forum/cache.ph...2FDSC08590.JPG

https://www.yenko.net/forum/cache.ph...2FDSC08591.JPG

Love it!!! I have a 55 2 door sedan that needs some of this same treatment, so I will be learning off this.

Got the last of the original floor remnants ground off this morning and lifted the floor into place with the lift for a trial fit. I gotta say, this floor fits about as good as anything you could get. I left as much of the original weld seams on the car as a reference and it matches very well.
I've put a number of 1 piece pans in vehicles now and it is still cool. I work 2-3 days getting ready for this and end up with a big hole and, wha-la, 1 piece and it looks like a vehicle again.

https://www.yenko.net/forum/cache.ph...2FDSC08597.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08598.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08595.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08596.JPG


Since that fit so well, I went after removing the left outer rocker cover the owner installed in 1970. I couldn't tell exactly where his seam was, so I just used the stone grinder to remove the edge of the metal, to preserve the original underneath.


https://www.yenko.net/forum/cache.ph...2FDSC08600.JPG


https://www.yenko.net/forum/cache.ph...2FDSC08601.JPG


I only saw the one spot weld and wondered why. I found out quickly when I started grinding off the paint. The whole seam is leaded...:tongue: That's tomorrow's removal process.


https://www.yenko.net/forum/cache.ph...2FDSC08602.JPG

Great job of rust repair there Mitch. This looks like a fun project. I know I will enjoy watching the progress of this one.:beers:

My uncle has a '55 handy man wagon. I'm about to start doing the same thing to it. I've already done the frame modifications so that wider tires will fit the rear.

I was on the tri-five.com website and read thru a gasser build. That guy flipped the stock spring mounts from side to side and moved the springs inboard of the rails. That is what I'm going to do to his. No frame mods at all.

I think this is what I used. https://www.performanceonline.com/19...caAl09EALw_wcB