Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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so, in the quest to find some metal, todays hour of stripping saw me take a lump hammer, chisel and knotwheel to the roof. what i found was pretty horrendous tbh. its all made of metal, and all fully welded (although the majority of the welds are all bubbly so either done without gas or done outside so it all blew away). its just the amount of filler over it all to get it the right shape is HUGE. the majority of the area ive stripped was all over 3/4" thick. this nothing short of a crater. the roof skin is actually concave where it should be convex- heres a couple of in-progress pics of me working down the side of the rear window. i opted to cut a trench through the deepest bit then chisel it out in chunks to save hours of knotwheeling, i only had to buzz off the thinner bits round the edge then. whats hiding underneath isnt amazing though- whats more, you cant see any of those cut/weld lines on the inside, they're all in different places, cos its all overlapped. all very confusing. that is nothing short of a f-kload of filler. thats not including all the stuff i turned to dust. good job it was a windy day! i also bolted the decklid back on its hinges, and removed the trim and handle off it. the shape flows pretty nice, but it needs a lot of work too, straightening up the outer skin, re-enstating the inner skin, and rust repair. the rest of the time today i carried on stripping the front wing id already started. this is actually quite good, theres evidence of a real old school body man working here, faint slapper and file marks used to dress out dents properly. the metal here is coming up good. theres a few coats of paint but most can be removed with the heat gun and scraper, only leaving bits of filler and the original paint and primer to sand off. i think that will go quicker once the new baseplate for my DA turns up so i can lock it into spinny mode rather than random orbital, as the other sander I'm currently using cant be locked. although, i have found a couple of rust holes. hopefully these don't spread to much-
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Last Edit: May 5, 2015 21:19:49 GMT by Dez
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vulgalour
Club Retro Rides Member
Posts: 7,082
Club RR Member Number: 146
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That's amazing. Seems a strange way to rebuild the roof by making it the wrong shape to start with and then just pile on loads of filler until it looks right again.
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Looking forward to seeing how you go about making that right! Will you be reusing anything of the existing roof that is already in place other than the window surrounds?
After going to all the effort to chop it you would have thought that whoever did it would have put the time in to get it closer to begin with
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bstardchild
Club Retro Rides Member
Posts: 14,886
Club RR Member Number: 71
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heres a couple of in-progress pics of me working down the side of the rear window. i opted to cut a trench through the deepest bit then chisel it out in chunks to save hours of knotwheeling, i only had to buzz off the thinner bits round the edge then. Sheesh - that is a lot of filler - no a lot doesn't cut it - that's a boat load of filler!!!!
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Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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the front half to two thirds of the roof is savable. the filler strip up the middle needs redoing cos its lapped under and has a load of filler, but thats not too much of an issue as i can just cut it out a bit wider and let a strip in. the bits above the rear 1/4 windows with the gutters and that are ok too, apart from being massively overlapped at the weld from the back of the rear window corner down to the decklid. those trim holes are like 3-4" below and you cant see through them as the overlap goes that far!
the major areas that need sorting are the roof skin above the rear window (i knew about this hence me stashing away a few roof skins of different curvatures to sort it), and the bits down each side of the rear window as well. by far the easiest way to sort it all out is to re-chop the car, chopping it a little more to take out the previous joins rather than try to clean them up. if i essentally take a strip out centred around the existing welds, i can do all fresh joins to my own satisfaction rather than trying to make good someone elses. it'll also allow me to sort the bad door gaps out too, they're closed up at the B-pillar. chop out the rear window section completely, remove all the overlapping bits, the reskin the roof above it and down each side.
this will give me a lot less joins, and i'll be working with all 'fresh' metal that hasnt previously been welded and ground on, so shouldnt do wierd things due to previous heat applied to the panel.
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RA40tony
Europe
Rollin' rollin' rollin'
Posts: 768
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Jeez!!!! Thats a lot of bodgery!!! But i'm sure you'll make it good and end up with an amzing custom. Really like the lines on the fastback shape!!
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1979 Toyota Celica GT. Currently Gone.
1975 Toyota Celica ST. 13x7 Allycats, "the stick" applied. 100kW 4AGE... Sold
1963 Karmann Ghia - Lo & Slo, Sold.
1965 VW Fastback - cruising
1953 Oval Ragtop, work in progress...
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This guy must of had shares in a filler company.... cant wait to see you start your metal work !
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2001 Micra 998 - Daily
1986 Mini Mayfair 998 - Former Daily - Garaged
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Are you sure you didn't accidentally bought a sculpture ? really ?
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sparkyt
Posted a lot
selling stuff
Posts: 1,767
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Cut the roof off wheel it and put it back on..... ?.
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awesome potential, actually does look like Holden's effigy, although a little late to the party, strip n clean disc in a grinder or a fiber disc with a rubber backing pad in a drill rips through filler, looking at your previous work with the other roof, cant see this presenting a problem, looking forward to seeing some more updates now good luck
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Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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This guy must of had shares in a filler company.... cant wait to see you start your metal work ! and i found a load more today! Are you sure you didn't accidentally bought a sculpture ? really ? yeah, i was thinknig that earlier as i dissapeared in a huge cloud of dust again... Cut the roof off wheel it and put it back on..... ?. i don't have an english wheel, nor the time and space to make one, so i'll be doing it by my own methods. you can wheel over welds anyway. i think my plan definatley invloves cutting the roof off though. awesome potential, actually does look like Holden's effigy, although a little late to the party, strip n clean disc in a grinder or a fiber disc with a rubber backing pad in a drill rips through filler, looking at your previous work with the other roof, cant see this presenting a problem, looking forward to seeing some more updates now good luck I'm doing this the way i am through mingebaggery more than anything. i don't want to throw a load of cash at blasting or buying abrasives/consumables, when i'll probably end up binning half the steel i find underneath. hence I'm stripping it using whatever stuff ive got laying round from other jobs. i've used up 2 of the 3 knotwheels i have left from the last car i stripped, i'm now using linishing discs(similar to what you mean, really rough sandpaper on a rubber backing disc) to rip the thick stuff off. the scraper and heatgun method is essentially free, removes all but the base layer of paint without smearing it around, and doesnt clog up loads of sanding pads. ive got a box and a half of 80 grit sanding pads i was given to strip the final coat off and put a finish on the metal, which should be enough to do the whole car.
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Last Edit: May 6, 2015 21:07:45 GMT by Dez
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sparkyt
Posted a lot
selling stuff
Posts: 1,767
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What ever choice of fixing the roof you do .
Your a far braver man than me . We're going to need pictures etc
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sparkyt
Posted a lot
selling stuff
Posts: 1,767
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What ever choice of fixing the roof you do .
Your a far braver man than me . We're going to need pictures etc
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Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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oh there will be plenty of those. after essentailly making the pick cab i posted pics of on the previous page from scratch, I'm sure i can manage this
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luckygti
Posted a lot
I need to try harder!
Posts: 4,912
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Good to see this getting some love mate, thoroughly deserving. And I thought my van had a lot of filler!
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Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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more paint and filler were removed in todays hour of power (tools). today i attacked the drivers side, just to hide out of the wind more than anything- you can see its changed shade of brown along the top half- thats because ive heat gunned and scrapered it all the way down to the original paint. it actually stripped really quick once i got going and got a bit of heat into the panel. the filler was just hacked away with a mega-rough linishing disc. this area was quite bizarre. you can see where there was loads of filler (where its a whiter/shiner finish as opposed to the bit thats still brown). pretty much the whole quarter had half an inch of filler on it, running much higher up than the other side. i was dreading what i was going to find, but the backside of the panel inside the car looked fine. and its seems it more or less is?! i need to make a profile gauge up to see if its the same curve as the other side, it coupld possibly be a bit flatter, but theres no obvoius damage at all? its also improved the door gap issue no end, they still don't quite shut, but now its by a couple of mil instead of quarter of an inch, so i hold out hope they can just be jacked to shape and braced up before redoing to the roof to hold them in place. i havent got a bloody clue whats going on with the door though. the bottom 4:"or so has been replaced, which is fair enough, its not even done that badly, the welds have been fully ground, although they are 'peaked', which i don't know if it will dress out, and there was filler over that. there was also a load of filler along the back edge, covering some damage (explainable i guess if the door was bashed against something), but i don't know what this is all about- it looks like someones cut up the edge, bashed it IN, not out, then tacked it back up? you can see wht should be a smooth curve dips in. i dunno. sortable i guess though, with some faffing. amazingly, this bit behind the rear arch is all original! as evidence by the paint. as you can see its now a bit, erm, ventilated, but it serves as valuable reference for what should be there. lastly,the fuel filler flap. litterally just the flap tack welded shut and fillerd over. theres still the panelwork to hold the cap and neck on the inside which runs between the 1/4 panel and boot floor. so thatll all be chopped out and skinned in properly, mostly cos i want to put an air tank where it is. so, nothing too nasty to report there though aside for the door oddness. it needs a lower 1/4 repair same as the other side but id be daft not to expect that. probaly end up throwing some new sills on too i guess, backed up with some box section to make them floor proof
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Last Edit: May 6, 2015 21:38:52 GMT by Dez
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vulgalour
Club Retro Rides Member
Posts: 7,082
Club RR Member Number: 146
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Dished in to accept more filler perhaps? I can't believe how much filler is still obviously left on there, it's insane.
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düdo
Part of things
wide as house
Posts: 770
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Great work taming those icebergs of filler! Looking sharp already. Is that your Ami in the workshop with its face peeking out behind?
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Isn't that why these were branded led sled's because of the amount of led poured over the roof chopped mettle work...
Looking forward to the new steel going in Dez I am really surprised non of that filler has lifted...
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Dez
Club Retro Rides Member
And I won't sit down. And I won't shut up. And most of all I will not grow up.
Posts: 11,712
Club RR Member Number: 34
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Great work taming those icebergs of filler! Looking sharp already. Is that your Ami in the workshop with its face peeking out behind? no, its belongs to a friend (who is on here but i will allow to remain anonymous if he wishes). quite a weldathon its turned out to be, but I'm getting towards the end now. Isn't that why these were branded led sled's because of the amount of led poured over the roof chopped mettle work... Looking forward to the new steel going in Dez I am really surprised non of that filler has lifted... to an extent yes, but if youve worked with lead youll know its actually hard to lay it on that thick. much more than 3/8" and its super difficult to work with. a lot of the filler has cracked, thats why its all coming off. all the stuff in the door bottoms and roof has cracked, and the stuff put on over the original paint can just be scrapered off.
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