ive got to make a repair to the sill in a car,it has to a good quality job, i was thinking of making a mold from flass fiber and then cement and forming the metal mostly on a sand bag to deep draw it then try and hydroforum it in the final shape with the mould supported in a steel support
- Thread starter squazy84
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malcolm
& Clementine the Cat
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That sounds a bit mad. My own approach would be eat a frozen pizza.
Then take the cardboard in the box and press it onto the rusty area to make a template. Pizza box behaves a lot like steel (though steel can be compound curved more than pizza box with a bit more effort). Yours looks like single compound curves mostly.
For a nice repair to rusty bit in the photo I can't see any more than a couple of little snips needed in the cardboard for it to follow the existing curves well. Make the metal the same and weld up the snips.
Then take the cardboard in the box and press it onto the rusty area to make a template. Pizza box behaves a lot like steel (though steel can be compound curved more than pizza box with a bit more effort). Yours looks like single compound curves mostly.
For a nice repair to rusty bit in the photo I can't see any more than a couple of little snips needed in the cardboard for it to follow the existing curves well. Make the metal the same and weld up the snips.
malcolm
& Clementine the Cat
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G`day Squazy
One thing i think is dying is the use-age of the K.I.S.S principle.
Keep It Simple Stupid.
That patch could be made with one piece os steel if you took your time, the pizza box (or any thin card for that matter) would give you all the information to make a perfect patch. Dont make things hard for yourself, a couple of bits of tube for the radius bends and a little hammer work give you a beautiful patch. Before you try to get complicated, stand back and see how simply you can do it first, simple is good......
One thing i think is dying is the use-age of the K.I.S.S principle.
Keep It Simple Stupid.
That patch could be made with one piece os steel if you took your time, the pizza box (or any thin card for that matter) would give you all the information to make a perfect patch. Dont make things hard for yourself, a couple of bits of tube for the radius bends and a little hammer work give you a beautiful patch. Before you try to get complicated, stand back and see how simply you can do it first, simple is good......
Are you replacing the whole sill or just the rusty section?
If your cutting out the rusty section and replacing it then you are patching the sill. The ridge that isnt shown wouldnt be the one that allows the door to align with the front wing would it?
With a little thought and some hammerwork you could replace the whole front section of the sill with 1 piece of steel, though making it in 2 or 3 parts would make it even easier.
There are many ways of doing it, the one you described would have to be one of the most time consuming and complicated of them. Doing this sort of thing can be enjoyable and full-filling or it can be complicated, expensive and frustrating. Its your choice mate, i was just offering my opinion.
Cheers
Troppo
its slightly forward of the joggle you speak of, i would just like to try an form it in one piece, less welding the better imo,it will always rust where it was heated,admittedly i kinda just wana try hyroforming and its just an excuse for me to buy a sand bag! its just a hobby,nothing to do with whats quicker or easier just interesting things for me to do! its a friends car we have in our shop and there's no timeframe,it is in the metal forming section and the part was originally stamped out in the first place
Fair enough mate, I`ve never personally done any hydro-forming but from what i`ve seen it can be fairly complicated to get accurate forming with it. If you want decent sand bags theres a great mob over here (in aus) that do them for the best prices i`ve seen
http://www.niftynotions.com.au/store/WsDefault.asp?Cat=panelbeaterbags
If you made the piece in a couple of pieces welded together and all cleaned up you can prime it before you weld in place or drill a hole in it and throw a heap of waxoil in it after you weld it in place then throw a rubber grommet in the hole
http://www.niftynotions.com.au/store/WsDefault.asp?Cat=panelbeaterbags
If you made the piece in a couple of pieces welded together and all cleaned up you can prime it before you weld in place or drill a hole in it and throw a heap of waxoil in it after you weld it in place then throw a rubber grommet in the hole
