55 Wagon Progress

[MP&C]

Our first task tonight was to modify die set #2 from last night so it would also tighten up the reverse joggle.





























Next, Die set #3 for adding the remaining folds. A partial bend is done in the magnetic brake, and then the die set forms them more accurately.




Before:









After....









Comparison:

















I like this method much better, looks to be more easily repeatable with better consistency.

[oletrux4evr]

This is the most amazing stuff I've ever seen. Just to be able to figure out how to do this is a cut above rocket science. You guys are wizards.

[DanStokes]

I can't figure out why this isn't your "day" job! You are SO clever and thoughtful around the challenges that come your way.

Dan

[MP&C]

Well, we have the new engine dropped in place.














....and she decided on fuel injection over the 770 CFM Holley (still new in the box). Of course this meant and O2 sensor bung on an already finished H-pipe. The bung that came with the FI Tech kit matched well to the outside radius of the exhaust pipe, but was rectangular in shape, and included a gasket for a "clamp installation"... As we aren't having any of that nonsense, the bung found it's way into the lathe, where a round outer perimeter will serve better for our TIG welded installation..





And after some touch up at the powder coaters....














Next, our arm rest enclosures for the rear seat needed a base for the padded arm rests. So Jake used the Go Kart slick to add some radius to 14 gauge cold rolled steel in order to match the enclosure...














.....and trimmed to fit....









These will be held in place with Mopar style door panel retainers, so we can still have ready access for any future maintenance on window mechanisms.

[MP&C]

Progress on the wagon...




Mike got the new fuel tank all prepped with the fuel pump...












Tank mocked up so we can do test fit/fabrication of the filler neck down to the tank...














An elbow will be needed to join these two together.









The local NAPA store had some smooth elbow exhaust pipe that we used to fabricate the complete filler neck, all the pieces were TIG welded together, and Dana powder coated the assy black for us.









Bracket we fabricated for bolting to the floor flange.



















Next, the drip rail area was scuffed well and the car inverted so we can seal the bottom of the drip rail to the top of the quarter area. This is using the self leveling sealer, so we needed to counter the gravity effect.














Next time we'll get the top side done..

[silver_bullet]

I don't think the GM engineers ever dreamed of this kind of precision....too many production compromises...

[pintoboy77]

As always great job!

[MP&C]

Thanks guys!


We found a flat spot in the drip rail that needed to match the rest, found a suitable worn jaw pair of Vise grips that was ripe for modification.

https://youtu.be/RgMLgJQ9Uqw

[MP&C]

Well, we've had about a month long hiatus as I've been in VA for the day job. Back to some wagon progress, we made a sanding block for the drip rail, this will get some PSA paper applied and sand away!









We did have a back up and punt moment. The factory style radiator that we had from Be-Cool did not have quite enough room behind the core support to use a cooling fan. Plus, it was questionable if the size would be enough for the 383 cooling needs. So we are going to use a cross flow, specifically the aluminum version for a V8 S10 pickup. Of course, this will require modification of the core support.









Shown above mocked up with the splash pan, the stiffening edge along the c-channel follows the splash pan. We need to insure any future version also clears the splash pan. Also note the three drilled holes in the side adjacent to the blue sharpie. These were added for our version of the AC car battery tray, so having the new upright just outside the old will allow us to bolt to the new upright on the inside, and keep the battery tray in the same locaton.









So the hired help started grinding out the spot welds that hold the lower radiator baffle in place.








After some modification, one side is taking shape. We will likely add some rings to the weldment to route the water hoses to the front side of the core support.









.....and more progress on the core support... Note comparison to old core support, we've added 3" in width to the opening.









As with most changes we've done to the wagon, we try to keep them subtle enough that they could be mistaken for factory.









Like so.....










Still need to add mounting brackets for the radiator and fabricate a new baffle, but happy with the results so far..




Yesterday we got some seam sealer applied in the drip rail. I had tried a few different brands over the years and have to say I'm really liking the Norton 97121 epoxy sealer. Really smooths out well.












Spreader was modified to help get things consistent, as well as pull the sealer up into the hemmed edge...

[DanStokes]

Where's her hearing protection?!!!! I have a permanent ringing in my ears because, as a kid, no one pushed hearing protection on me. Wish they had.

The mods are looking good!

Dan

[MP&C]

What? What? yeah, you're right. We did have the air pressure down to about 60 psi so it wasn't as bad, didn't want the burr grinder getting away from her..

[DanStokes]

Tell her "Grandpa Dan says WEAR YOUR HEARING PROTECTION!!!!" I'm not shouting, just talking over that annoying ringing sound.

Dan

[hauen]

Years working next to athey wagons and self-loading scrapers on construction grades has left me with that annoying ringing too. I'm always on the kids to not crank their headphones and real big on hearing protection now, but irony of ironies, no one listens.

[JOES66FURY]

WHAT?

Working on jet engines for 23 years, being around operating aircraft, diesel generators, diesel trucks, air compressors, air tools and the like I have constant ringing in both ears...it is maddening...get some ear defenders on young lady!!!

amazing work as always!

[MP&C]

So we had fabricated a duplicate of the 55 AC car battery tray to get the battery off the firewall. This bolts directly to the outside of the core supports "horseshoe".














So when we decided to widen the opening for a crossflow, the tubing had to be placed directly next to the old upright to locate our battery support in the same location.









This means the new uprights would also conflict with radiator necks. Dominoes, they do fall.... Core support now with relief holes for coolant hoses and lines. Thankfully side baffle plates will hide this ugliness!














Video Version:

https://www.youtube.com/watch?v=VRojQ4nWMhw

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