DDK - Die Deutschen Klassiker

Cheers mate thanks a lot

sladey wrote: Whatever - I've got to finish my shed before I can get back to the panel beating and welding
Mark

Well that's done then (http://www.ddk-online.com/phpBB2/viewto ... &start=105)

So I'm back onto the task I stopped about a year ago.

a couple of weeks ago I had to repair my exhaust back-box and I tried the pulse/spot welding technique - worked an absolute treat, was much more controllable and produced a nice series of welds.

So I finally returned to the wing I've been working on.


this bit needs some attention. There's a rust hole at the bottom, part of the supporting flange has gone a bit lacey, and there is also a previous repair there.
There are 2 bits that need making - the dimpled supporting strut thing you can see (with the two holes in it) and also the metal it sits on - that's got the rust hole in it. There's a gap behind it so crud will have got in there and rotted it a bit.

So out with the cornflakes packet and after a bit of beating and shaping I'd got this



Then I wanted to make the dimple/pressing in the middle to give it a bit more strength, so I started out with a hole


And a bit of beating later I got to this


and then this


Thinking about it later it would have been better to produce a 'male' buck instead of a female one - might have lead to fewer marks in the metal. One to remember for next time.

I was quite happy with this initially


But then I looked round the back I knew it was going too well


You can't see it wonderfully well in the pic but there is a flange that curls under from the metal underneath and my new dimple was getting in the way!

Time to bring in the persuader

First I chopped off part of my jig


then after a bit more persuasion I created enough space for the flange


Here it is held in place

Next to start on the bit of metal underneath - I first hammered a flange over and then started to put kinks into it to create the necessary curve


After a lot more kinking, heat shrinking and beating I ended up with this:-


So the two pieces will fit together like this:-


This week-end I'm hoping to do a bit of cutting and welding.

Great job - a Barry Carter in the making!

sladey wrote:
.........so I started out with a hole

That's where all the problems start......

Great stuff Mark, very impressive...!

All finished for July ?

Dunno about that - might have one wing on in primer - maybe paint - we'll see

Love the primer look

Good week-end's work:-

Cut out the rusty (er) bits



Weld in the bottom bit


And the top bit


Wih the support done, time to make the outer skin (this is my third attempt - previous ones either didn't get the shape or had too many hammer marks)


Just resting in place


Tacked:-


First few welds


Done


And smoothed off:-


I was really happy with this. I tapped down a high spot and caused a minute crack in one of the welds - still learning, but enjoying the process. The pulse-style welding is really working for me - I can see where the next weld is to go - whereas when I try and lay a bead I sometimes go off-line and don't know what to do if it goes wrong. The pulse welding just works and looks neat

Top man
Well done

Thanks Jonathan,

I'm enjoying the journey for it's own sake, and each mistake is a new lesson. However the latest job started to feel like progress was being made and I might actually put this wing on the car one day.

Yup, agree making progress is a necessary part, gives you a bit of a boost, look forward to seeing more !

Fantastic work Mark