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Bolens 1053 Return to Service Project


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#196 29 Chev OFFLINE  

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Posted January 22, 2017 - 05:46 PM

Like most labours of love it takes time and as others have said the result should last quite a while and the investment will be worth it to me.

 

Took the wire brush to the fender today and started to clean it up - worked away on it outside as it was unusually mild - about 43 degrees F here.  I noticed some pitting in the metal that formed the ribs where the slots are to mount the seat so I decided to add some reinforcement on the under side of the ribs using two 1/8 x 1-1/4" x 11-3/4" pieces of flat steel - this should prevent any cracking of the fender where the pits may have weakened it.  Drilled two holes at the end where I wanted the slots to be and then used the die grinder with a cutoff blade to cut the slots out between the holes.  Once that was done I tack welded the two pieces of steel to the bottom of the ribs, filled in the hole someone had made at the rear of the fender, straightened the fender a bit more where I welded the pieces in and also smoothed up the lip at the outer edge. 

Attached Thumbnails

  • 1 Top Wire Brushed.jpg
  • 2 Top Wire Brushed.jpg
  • 3 Top Wire Brushed.jpg
  • 4 Bottom Wire Brushed.jpg
  • 5 Pitting At Ribs.jpg
  • 6 Pieces Of Flat Metal Cut And Holes Drilled For Slots.jpg
  • 7 First Cut With Cut Off Blade To Make SLot.jpg
  • 8 Making Slots In Flat Pieces.jpg
  • 9 Slots Made.jpg
  • 10 Pieces Spotted In Place.jpg
  • 11 Welds Cleaned Up.jpg
  • 12 Edges Straightened.jpg
  • 13 Edges Straightened.jpg
  • 14 Edges Straightened.jpg

Edited by 29 Chev, January 22, 2017 - 06:06 PM.

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#197 KennyP OFFLINE  

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Posted January 22, 2017 - 06:11 PM

Nice fix!


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#198 29 Chev OFFLINE  

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Posted January 23, 2017 - 04:51 PM

Spent about four hours wire brushing and sanding the fender in hopes that I can start applying body filler tomorrow - also found a few little dents that I had missed and straightened them as best I could.  It rained here this morning and as a result the air was a damp 40 degrees F - not real warm but quite mild for this time of year - here are the results. 

Attached Thumbnails

  • 1 Fender Sanded.jpg
  • 2 Fender Sanded.jpg
  • 3 Fender Sanded.jpg
  • 4 Fender Sanded.jpg
  • 5 Fender Sanded.jpg
  • 6 Fender Sanded.jpg
  • 7 Fender Sanded.jpg
  • 8 Fender Painted.jpg

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#199 KennyP OFFLINE  

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Posted January 23, 2017 - 05:12 PM

Hope you can get the humidity down to workable levels!


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#200 29 Chev OFFLINE  

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Posted January 24, 2017 - 05:23 PM

Moved the fender into the heated shop and started to apply body filler - put a bit of filler on the bottom side where I welded the pieces in at the front and filled the hole in at the back so that there would be very few recesses for dirt to sit in.  Once I applied and sanded a few coats of filler I got the bottom side to the point that I could spray it with self etching primer - still have to finish the top side which will require a few more filler applications and sanding.

Attached Thumbnails

  • 1 Body Filler Applied.jpg
  • 2 Body Filler Applied.jpg
  • 3 Body FIller Applied.jpg
  • 4 Bottom Sprayed WIth Self Etching Primer.jpg

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#201 29 Chev OFFLINE  

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Posted January 25, 2017 - 03:05 PM

Did some more filler application and sanding until I got the fender to where I could live with it (or you might say I got tired of sanding and filling - body work is not my most favorite job).  Applied some self etching primer and after that dried I gave the fender a few coats of sandable primer and let everything dry for a good thirty minutes.  Then I flipped the fender back over and gave the bottom a coat of paint.  Will still have to do some more sanding on the top side but at least it shouldn't rust much now.

Attached Thumbnails

  • 1 Rear Corner Filler First Coat Sanded.jpg
  • 2 Front Coming Slowly.jpg
  • 3 Self Etching Primer Applied.jpg
  • 4 Self Etching Primer Applied.jpg
  • 5 Bead Around Shifter Opening.jpg
  • 6 Red Primer Applied.jpg
  • 7 Front Opening.jpg
  • 8 Bottom SIde Painted.jpg
  • 9 Bottom Painted.jpg
  • 10 Back SIde Of Opening.jpg
  • 11 Bottom Painted.jpg
  • 12 Bottom Painted.jpg

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#202 29 Chev OFFLINE  

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Posted January 25, 2017 - 03:11 PM

While I was waiting for body filler and primer to dry I had a good look at the dash support as it will need a bit of work as well.  There are two studs that are broken off, one that is bent, and it is badly pitted along the left lower edge - I assume from grass and battery acid sitting against it.  Will also have to fix a couple of cracks where the two upper corner studs that hold the dash on are and straighten the edges a bit but at least nothing has been cut out of it.  

Attached Thumbnails

  • 1 Dash Support Studs.jpg
  • 2 Dash Support Studs.jpg
  • 3 Left Lower Edge Badly Pitted.jpg
  • 4 Front Edge Bent.jpg
  • 5 Left Upper Edge Cracked At Stud.jpg
  • 6 Right Upper Edge Cracked At Stud.jpg

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#203 29 Chev OFFLINE  

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Posted January 26, 2017 - 03:28 PM

Gave the top side of the fender a good sanding and another priming and sanding and then it got painted.  Got a few runs and dirt in it and it still has a few waves but I am happy with the results considering what it looked like when I started on it.

Attached Thumbnails

  • 1 Top Of Fender Painted.jpg
  • 2 Top Of Fender Painted.jpg
  • 3 Top Of Fender Painted.jpg
  • 4 Top Of Fender Painted.jpg
  • 5 Got A Run In It.jpg
  • 6 Shifter Opening.jpg
  • 7 Left Side.jpg
  • 8 Right SIde.jpg
  • 9 Has A Few Ripples.jpg

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#204 29 Chev OFFLINE  

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Posted January 26, 2017 - 03:32 PM

Moved on to cleaning up the dash support using the wire brush - got it cleaned up enough that I can start fixing the cracks and replacing the broken and bent studs as well as cutting out and replacing the rusted area at the left lower edge at the rear. 

Attached Thumbnails

  • 1 Dash Support.jpg
  • 2 Dash Support.jpg
  • 3 Left Lower Edge Rusted At Rear.jpg
  • 4 Cracked Around Left Upper Stud.jpg
  • 5 Cracked Around Right Upper Stud.jpg
  • 6 Left Lower Edge Rusted At Rear.jpg
  • 7 Left Upper Stud Cracked Under Decal.jpg
  • 8 Right Studs Cracked Under Decal.jpg
  • 9 Rear Side Of Support Wire Brushed.jpg

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#205 KennyP OFFLINE  

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Posted January 26, 2017 - 04:21 PM

Looking mighty good there!


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#206 fonz3482 ONLINE  

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Posted January 26, 2017 - 07:36 PM

Awesome work!
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#207 29 Chev OFFLINE  

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Posted January 27, 2017 - 07:04 PM

Thanks for the kind words.

 

Started to repair the dash support today - tried to straighten the bent stud but the stud weld broke instead while I was trying to bend it so it got removed leaving a hole with a few cracks around it.  Ground out the cracks around the hole as well as the cracks around the two upper studs using the die grinder with the cutoff blade, welded them in with the mig welder and then cleaned up the welds with the cutoff blade and a 2" roloc grinding disc.  I decided that my nerves of jelly would not be able to hold a new stud steady enough to weld it in place and ninety degrees to the panel so I made a jig out of a scrap piece of 1/4" flat steel.  I drilled a 1/4" hole in the middle and then drilled the one side out to 3/8" about three quarters of the way through the steel and then I welded a 1/4" UNC nut on the 1/4" hole side.  This left me with a jig that I could thread a stud into and then clamp the assembly to the back side of the panel - the 3/8" side of the hole left clearance around the stud for the weld to penetrate without it sticking to the jig.  I cut the heads off three 1/4" x 1" UNC bolts to make new studs - left them about 3/4" long to match the old studs and threaded one into the jig and set it over the hole from the missing stud and checked for clearance to turn the jig - the corners were sticking out so I cut two corners off of the piece of flat steel which let it clear to rotate as once the stud was welded the jig would have to be threaded off the stud to remove it.   

Attached Thumbnails

  • 1 Cracks At Left Upper Stud Ground Out.jpg
  • 2 Right Side Cracks Ground Out.jpg
  • 3 Cracks Welded.jpg
  • 4 Cracks Welded Back Side.jpg
  • 5 Cracks Welded Back Side.jpg
  • 6 Welds Ground Back Side.jpg
  • 7 Welds Ground Back Side.jpg
  • 8 Welds Ground Left Side.jpg
  • 9 Welds Ground Right Side.jpg
  • 10 New Studs Made From Bolts.jpg
  • 11 Scrap Piece Of Quarter Inch To Make Jig.jpg
  • 12 Three Eights Hole Drilled Partially Through.jpg
  • 13 Corners Cut Down So It Can Be Turned Off.jpg
  • 14 Nut Welded To Quarte Inch Hole Side.jpg
  • 15 Centred Over Hole To Make Sure It Would Clear While Being Turned.jpg
  • 16 Stud Threaded Into Jig.jpg

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#208 29 Chev OFFLINE  

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Posted January 27, 2017 - 07:20 PM

I clamped the jig with the stud to the back side of the panel using two pairs of vise grips, threaded the stud so that the end was a little below the panel and welded it around the hole with the mig filling the hole area in.  Then I did a test fit with the dash to see that it still fit the studs - it did so I ground the weld on the outside and then I ground the two broken studs off flush with the back side of the panel.  Then I mounted the dash back in place and marked out where to drill two holes so I could weld two new studs in the same way I did with the hole left from the bent one.  Once the locations were marked I drilled two 1/4" holes and welded two new studs in, ground the welds on the panel side and tried the dash in place to make sure things still fit.  Things looked good so I ran a 1/4" UNC die over the threads of the studs to remove any burrs and weld slag, put flat washers and nuts on the studs and tightened them up to test the integrity of my welds - the studs held without any signs of cracking so I removed the dash and turned my attention to the rusted area at the bottom edge.  

Attached Thumbnails

  • 1 Jig Clamped In Place With Vise Grips.jpg
  • 2 Stud Ready To Be Welded.jpg
  • 3 Stud Welded In Place And Jig Unthreaded.jpg
  • 4 Stud Welded Outside View.jpg
  • 5 Test Fit Of Dash On Studs.jpg
  • 6 Weld Ground Outside.jpg
  • 7 Broken Studs Ground Off Flush.jpg
  • 8 Dash Bolted In Place To Mark Holes For Studs.jpg
  • 9 Test Fit Of Dash After Welding New Studs In.jpg
  • 10 Welds Ground On Outside.jpg
  • 11 Welds Ground On Outside.jpg
  • 12 Left Stud Welded Back Side.jpg
  • 13 Right Stud Welded Back Side.jpg
  • 14 Centre Stud Welded Back Side.jpg
  • 15 Nuts Tightened To Make SUre Studs Held.jpg

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#209 29 Chev OFFLINE  

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Posted January 27, 2017 - 07:26 PM

Cut out a new piece of metal to replace the rusted section on the dash support - drilled a hole in it and bent the lip to match the section it was replacing.  Once that was done I marked out where it would fit, cut out the rusted piece and welded the new piece in.  I also welded in a section of one of the slotted bolt holes that had broken out and a crack on the right lower corner that had formed.  Then I sanded the welds and here are the results.

Attached Thumbnails

  • 1 New Piece Cut To Replace Rusted Area.jpg
  • 2 Marking Out Section To Be Cut Out.jpg
  • 3 Rusted Section Cut Out.jpg
  • 4 Rusted Section Cut Out.jpg
  • 5 New Pece Welded In.jpg
  • 6 New Piece Welded In.jpg
  • 7 Right Lower Corner Crack Welded.jpg
  • 8 Bolt Hole Slot Welded.jpg
  • 9 Right Lower Weld Sanded.jpg
  • 10 Patched Area Sanded.jpg
  • 11 Patched Area Sanded.jpg
  • 12 Bolt Hole Slot Sanded.jpg
  • 13 Bolt Hole Slot Sanded.jpg

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#210 KennyP OFFLINE  

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Posted January 28, 2017 - 06:20 AM

I like your stud holder! Good idea!  Nice fixes!


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