Found another Chevy

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retro-roco
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Re: Found another Chevy

Post by retro-roco » Thu Sep 15, 2016 5:58 pm

Jon,
You never cease to amaze! I'll be looking forward to seeing your finished fender!
Kirk Gustafson
359th Infantry Regt. 90th Div. WWII HRS

1942 Chevy G506 1-1/2 ton 4x4 Cargo
1943 Ben Hur water trailer


gentrysgarage
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Re: Found another Chevy

Post by gentrysgarage » Thu Sep 15, 2016 6:21 pm

Love it...Know it all to well...
Thanks for posting!
Proud caretaker of U.S.A. truck 3219442-S 1943 Chevrolet Cab Over Engine 1 1/2 4x4

kelley
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Re: Found another Chevy

Post by kelley » Fri Sep 16, 2016 3:35 pm

Thanks Guys,
I made some more progress this afternoon after work....
As cut the 2 halves were oversized by about +/- 5/32nds of an inch.
Right fender repairs-1.jpg
Right fender repairs-1.jpg (104.81 KiB) Viewed 1247 times
It took 3 tries with the flap wheel to get the fit where I wanted it
Right fender repairs-2.jpg
Right fender repairs-2.jpg (151.29 KiB) Viewed 1247 times
Here's a close up of it fit and tacked....
Right fender repairs-3.jpg
Right fender repairs-3.jpg (142.51 KiB) Viewed 1247 times
Maybe tomorrow I can finish it up....
Right fender repairs-4.jpg
Right fender repairs-4.jpg (176.55 KiB) Viewed 1247 times
Kelley

D.R.H.
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Re: Found another Chevy

Post by D.R.H. » Fri Sep 16, 2016 4:19 pm

All this TALENT to save a fender and you can't see your way through to start re-producing Chevy beds for yourself and the rest of us Jon!?!? Whiskey Tango Foxtrot, Mister?? :) Seriously though, it looks great!!
In Loving Memoriam: George R. Hancock. 20 Mar. 1938 - 11 Jan. 2017. U.S.A.F. 1956 - 1962. R.I.P. Dad.
In Loving Memoriam: Ann Hancock, 08 Mar. 1934 - 25 Sept. 2021. R.N. 1960 - 2005. R.I.P. Mom.
Thank You BOTH for always being there.

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kelley
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Re: Found another Chevy

Post by kelley » Sat Sep 17, 2016 3:51 pm

Hey Dave,
D.R.H. wrote:All this TALENT to save a fender and you can't see your way through to start re-producing Chevy beds for yourself and the rest of us Jon!?!? Whiskey Tango Foxtrot, Mister?? :) Seriously though, it looks great!!
One of my "Montana" fenders wasn't exactly rust free :cry: , I had to make the best of it. Yes, I could reproduce Chevy bodies and I'm sure they'd come out great, But the cost would be thru the roof :( and I'm sure shipping would be a deal breaker too :( .
Here's the last of my fender adventure....
To hide the weld joint I like to start out with a 5'' hard wheel and carefully bring the weld down flush with the base metal using the edge of the wheel.
Fender repairs-1.jpg
Fender repairs-1.jpg (132.25 KiB) Viewed 1223 times
I then polish it up a little with a flap wheel to hide some of the grinder marks.
Fender repairs-2.jpg
Fender repairs-2.jpg (124.4 KiB) Viewed 1223 times
Here it is all cleaned up....
Fender repairs-3.jpg
Fender repairs-3.jpg (138.26 KiB) Viewed 1223 times
Here it is all primed up, you can still see a few grinder marks.
Fender repairs-4.jpg
Fender repairs-4.jpg (113.82 KiB) Viewed 1223 times
Fender repairs-5.jpg
Fender repairs-5.jpg (156.85 KiB) Viewed 1223 times
Fender repairs-6.jpg
Fender repairs-6.jpg (149.84 KiB) Viewed 1223 times
Here's the jig I made to make it happen, If anyone want it, it's all yours.
Fender repairs-7.jpg
Fender repairs-7.jpg (142.28 KiB) Viewed 1223 times
I'm looking for a pair of under fender supports if anyone has a spare set....
Fender repairs-8.jpg
Fender repairs-8.jpg (147.06 KiB) Viewed 1223 times
Kelley

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Re: Found another Chevy

Post by forestry4evr » Thu Sep 22, 2016 8:09 am

Jon,

That is just too cool. Did you use the jig as a cutting fence, and did you cut the fenders with a cutoff wheel on a side grinder? You mentioned you cut both sides 5/32 oversized...did you then grind/fit until both fender halves matched the jig? Sure wish I possessed your metal working skill...or even 50% of it.

Paul
1941 G4112 Chevrolet with Hercules dump bed

kelley
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Re: Found another Chevy

Post by kelley » Thu Sep 22, 2016 4:00 pm

Hi Paul,
The "Fence" for lack of a better name was mounted roughly perpendicular to the mounting flange side of the fender. I located it where I did because 1 fender had some rust thru and lots of deep pitting on the front, the rear half was in amazingly good shape. The other fender only had a good front half, the rest of it also had rust thru and lots of deep pitting. Basically that was the only place to cut both fenders and have only 1 splice.
Here's a more detailed explanation of my procedure....
-All layout was done off of the FORWARD most edge of the fence.
With the jig bolted to the fender that had a good rear half, I used a short piece of 5/8'' wide bar stock pressed up against the fence, I then dragged a SHARP soapstone along the edge of the bar creating a neat, thin line parallel with the fence but 5/8'' forward of it.
Right fender repair-4.jpg
Right fender repair-4.jpg (158.24 KiB) Viewed 1175 times
Using a 5'' angle grinder with a cut off wheel (Shop slang is Wiz wheel), I cut this fender not on the line but just forward of it leaving the line. So my cut edge is +5/8'' from the forward edge of the fence.
Next step is to bolt the fence up to the fender with the good front half.
On this fender I used a 1/2'' wide bar to drag the soapstone against, and cut on the rear side of the line, ending up with a cut that is -1/2'' from the fence.
Right fender repair-3.jpg
Right fender repair-3.jpg (147.16 KiB) Viewed 1175 times

Both halves are now slightly oversized, with one half bolted to the jig, the other half will not bolt up, by about a half a hole.
Right fender repairs-1.jpg
Right fender repairs-1.jpg (104.81 KiB) Viewed 1175 times
From here I used a 5'' angle grinder with a flap wheel ( shop slang is Flap Wheel) :P to carefully sand the edges until the bolt holes on the front half aligned with the holes in the jig. At that point getting the 2 halves aligned in plane was the next step prior to tacking them together.
I hope this explains it better, I'm much more able to do the work than trying to type out a long winded explanation with my fat little fingers.
Kelley

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Re: Found another Chevy

Post by forestry4evr » Fri Sep 23, 2016 10:22 am

Jon,

Thanks for answering my questions. You transferred the process to written form very well. Actually you did fine the first time too, I just wasn't paying close enough attention. That looks like a transfer method that could be applied for other splice jobs. I need to do something similar to one of the cab floor "legs" and will attempt to incorporate your technique. Thanks for the novel idea. Your freehand skill with the Wiz Wheel is killer. It looked like you used the jig as a fence with some other metal cutting device.

Do you weld both sides on a seam like that fender? I do when it is not in a blind area, but wondered if it was really necessary. It always seems that welding both sides would increase the strength. Overkill?
1941 G4112 Chevrolet with Hercules dump bed

kelley
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Re: Found another Chevy

Post by kelley » Sat Sep 24, 2016 4:35 pm

Moving on to the inner fender I came across a very common problem with broken/rusted spring clips ( the one's that secure the bottom of the engine side cover). I had other inner fenders to steel clips from.
spring clips-1.jpg
spring clips-1.jpg (150.56 KiB) Viewed 1145 times
I have some brake lining rivets that I thought would make short work out of this little repair, but I couldn't find them so I ended up making my own, here's how I did it....
First step was to take 2 small pieces of bar stock, clamping them together and then drilling a 3/16'' hole in the joint between the plates. I then cut a bunch of short pieces of 3/16'' wire x 9/16'' long.
spring clips-3.jpg
spring clips-3.jpg (144.05 KiB) Viewed 1145 times
The head of the rivet is a pan head, I thought it would be easier to form hot so I warmed up the piece in the block prior to hammering it.
spring clips-4.jpg
spring clips-4.jpg (101.81 KiB) Viewed 1145 times
Once you have the stock a dull to bright red drive the material into the block with the face of the hammer, try and keep the head centered on the shank of the rivet (practice makes perfect). Once it looks like the head of a nail, use the toe of the hammer to round over the edges to create a pan head.
spring clips-5.jpg
spring clips-5.jpg (122.21 KiB) Viewed 1145 times
Here's what they will look like....
spring clips-7.jpg
spring clips-7.jpg (140.3 KiB) Viewed 1145 times
Here's what the forming tool looks like....
spring clips-8.jpg
spring clips-8.jpg (123.04 KiB) Viewed 1145 times
Here's the knock offs next to OEM
spring clips-2.jpg
spring clips-2.jpg (110.96 KiB) Viewed 1145 times
I thought it best to set the rivets cold to avoid heating up the spring clip and side cover. I used some scrap flat bar and vice grip clamps to buck the rivets and a 1lb ball peen hammer to set them.
spring clips-9.jpg
spring clips-9.jpg (114.81 KiB) Viewed 1145 times
I used the ball end to set them cold and create a pan head.
spring clip-1.jpg
spring clip-1.jpg (103.75 KiB) Viewed 1145 times
Here's the finished product....
spring clip-2.jpg
spring clip-2.jpg (111.72 KiB) Viewed 1145 times
Kelley

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Re: Found another Chevy

Post by kelley » Sun Oct 09, 2016 9:07 am

I made some progress on the cab steps, The ones that were on the truck were not worth messing with.
cab stepss-4.png
cab stepss-4.png (114.35 KiB) Viewed 1109 times
cab stepss-3.png
cab stepss-3.png (101.32 KiB) Viewed 1109 times
The Outriggers from my experience are often bent or rusted and need some work to be serviceable, mine were no exception. The outriggers on this truck were bolted to the frame which tells me they have been replaced at least once in the life of the truck, from what I've seen the originals were riveted to the frame.
cab steps-1.jpg
cab steps-1.jpg (115.18 KiB) Viewed 1109 times
The 2 outboard ones were on the truck (moderate rust) the inboard pair were on the replacement steps I got from G member "Bacon" (Thanks Ken) :D . They all need work.
cab steps-2.jpg
cab steps-2.jpg (153.11 KiB) Viewed 1109 times
Here they are all cleaned up and ready to go.
cab steps-7.jpg
cab steps-7.jpg (104.57 KiB) Viewed 1109 times
I stripped off all the hat channels and gas can brackets by drilling thru the spot welds.
cab steps-3.jpg
cab steps-3.jpg (141.4 KiB) Viewed 1109 times
Drivers side gas can bracket.
cab steps-6.jpg
cab steps-6.jpg (163.48 KiB) Viewed 1109 times
cab steps-8.jpg
cab steps-8.jpg (128.63 KiB) Viewed 1109 times
cab steps-9.jpg
cab steps-9.jpg (131.5 KiB) Viewed 1109 times
I'm going to install this gas can support on the left side and make an opposite hand one for the right side to help stiffen up the cab steps.
cab steps-9a.jpg
cab steps-9a.jpg (130.23 KiB) Viewed 1109 times
Kelley

phillip.w.givens
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Re: Found another Chevy

Post by phillip.w.givens » Fri Oct 21, 2016 4:50 pm

Kelley great work on the fender and the steps. When you get to the fuel can mounts can you make some drawing of the pieces needed for them.

Phillip
1942 chevy G506
1942 G7113 Tractor

kelley
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Re: Found another Chevy

Post by kelley » Sat Oct 22, 2016 3:46 pm

I finished up the cab steps, these were a lot of work.
running boards-2.jpg
running boards-2.jpg (138.22 KiB) Viewed 1035 times
running boards-1.jpg
running boards-1.jpg (140.25 KiB) Viewed 1035 times
Work'n on it Phillip...
Gas can support-1.jpg
Gas can support-1.jpg (77.88 KiB) Viewed 1035 times
Kelley

Ian Mastin
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Re: Found another Chevy

Post by Ian Mastin » Sat Oct 22, 2016 4:28 pm

Hi Kelley,

Is their any chance I could get a copy of the card broad templete of the jerry can holder mounting bracket's please.


Kind regards
Ian Mastin :)
MB 311192 ARN 157967
Gpw 161919
Aus Trailer No3a, 43
Aus Trailer No4, 45
41 Fordson WOT2-H
G506 Chevy

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retro-roco
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Re: Found another Chevy

Post by retro-roco » Sat Oct 22, 2016 4:46 pm

I'll just throw this out there... Jon, If you want to send it to me (or a copy of it), I'll draft it up and post a PDF file that can be downloaded by anyone who wants it...
Kirk Gustafson
359th Infantry Regt. 90th Div. WWII HRS

1942 Chevy G506 1-1/2 ton 4x4 Cargo
1943 Ben Hur water trailer

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retro-roco
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Re: Found another Chevy

Post by retro-roco » Sat Oct 22, 2016 4:47 pm

Nice work Jon. I wasn't sure what your plan was on the running boards. I wasn't sure if you were saving the running boards or the hat channels. It's all clear now!
Kirk Gustafson
359th Infantry Regt. 90th Div. WWII HRS

1942 Chevy G506 1-1/2 ton 4x4 Cargo
1943 Ben Hur water trailer


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