05 December 2011

the missing link

Remember that update I just did on the hurtlocker truck right?
Well I finally found the cellphone pics that covered the same time frame.
That gap of time right after the patch panels were set.

cab patch panel



























It's like unearthing an archaeological find.
The missing link.

If you look closely,
check out that gap between the door and the hump there.
That shows how much bondo was needed,
as the cab corner attaches to it.

slice and dice


























This door jamb section was smacked hard.
The new door amplified how far off it was.

wacked


























For months I had seen this section,
subconsciously figuring it out how to fix it.

2nd layer

























I had tried bending it.
I had tried hammering it.
I had tried clamping it and pulling it with a twisted rope.
I didn't want to heat it and hammer it as the section is too large.
Besides finding a replacement section,
cutting, hammering, welding and grinding prevailed.
Typical.

stitched

























Those months of study paid off,
cause the fix only took a couple hours.

magic paint
stool cameo


























Now that the door jamb matched the door,
the original cab corner was fit in.

rough fit


























Here you can see how bad the piece was,
even after hammering.
I was concerned that too much hammering would stretch it out,
farther than the door.
Well obviously I overthought that part.
Anyway if you look closely,
check out the black sharpie line next to the door.

major realignment

























It was off a ton.
Also look at the rear peak where the patch panels meet.
Nothings easy.

trimmed

























That section had to be cut out,
and that is why that other piece had to be welded in.

mini panel
from earlier post


























With this part roughed in,
a new peak was hammered out,
and crudely installed.

almost there

























As you can see it also got a little smoother.
This was after some really tough left hand hammering.
Hammering on this was probably not the smartest way
to test my ambidexterity,
but who has time to practice right!

magic paint

























After a thick coat of epoxy,
it look alot better,
but far from perfect.

last patch panel


























That paint is so strong,
that it is possible to hammer on it with out flaking.
Well before it is totally cured anyway.

If you remember,
I put it on thick with a mini-roller,
so that splotchiness is just the goopiness of the paint.

work truck



























It will still need a good filler coat to smooth out,
but it was good to know what to do next time.
Buy a better cab!

TP

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