Sunday, December 13, 2015

Mind the gap

Xavier removing the door handle and lock cylinder

While the engine is out at the machine shop, I returned to the body, starting with the doors. Since I'm already thinking about the repaint, I need to start working some odd and damaged things that I've noticed along the way, not the least of which is the way the doors hang. See the pictures and you'll notice what concerns me: the gaps between the panels on this car need adjustment, but neither door is even close to being aligned. The body lines dodge all over when going through the doors and it bugs me. I need to consider several things when approaching potential solutions:
  1. The driver's door is not the original
  2. The car had both quarter panels replaced in an earlier restoration
  3. The doors appear to have never aligned right in the pictures depicting the older resto results
That seam is kinda janky, door creaks as well

What, me worry?

Gotta admit, in the back of my mind I'm thinking that it is within the realm of possibility that the body wasn't braced when the past owners cut out and installed the new quarter panel sheet metal. And if that hunch is correct, the body could have flexed during the process, and the doors may never hang right. It's all speculation regardless. Even if true, we can't let that stop us. So Xavier and I decided to work with what we got. The strategy we decided on is to start at the rearmost doorseam- the one we can't really do much about (unless we cut out and reinstall the quarters, which ain't gonna happen), and when we have that seam looking good, adjust and re-hang the fender up front to get the front seam looking good. We acknowledged that we may need to rework some sheetmetal on the door skin to get our body lines sorted. Did I mention we're making this up as we go? Being that we are bone noobs at bodywork, if anyone out there has expertise, or would like to lend a hand, we're pretty receptive!

Permission to treat the witness as hostile, your excellence?

The piece in my hand is supposed to be attached
There are secondary reasons we decided to dismantle the doors, one of which is the presence of a big dent on the interior of the driver's door which will need attention, and some klunky action on some of the windows. We set out to remove the glass, regulator, door latch, and wing window assembly from the passenger door. Got some surprises when doing this! First surprise was that the window wasn't really attached, only gravity was holding it in, so when I pulled up, it just came out. Glad for good grip, since I didn't fling the window across the freakin room. Surprise #2 was the wing window assembly (isn't that the part Ralph Nader got all bothered about back in the day?)- When removing the assembly I discovered that on of the pop metal mounting tabs was sheared off. So the entire wing window assembly was attached with a single bolt. When reassembling the door, we'll endeavor to, you know, attach things and stuff. Third surprise was the rust under the rearview mirror mount, which I took care of with a grinder


Removing window trim
Not sure we actually had to remove every last mechanism from the door, but since we've never done it, it sure was interesting to learn how all of it goes together. And I'll tell you, the door weighs considerably less now that it's just a sheet metal shell. This should make all the fitment adjustments a whole lot easier. We can just prep and paint the thing too, without having to mask, also a plus. On the driver's side we'll probably just remove the glass, handles, and the trim.



More photos

Pretty dirty down in the door, plus more mud dauber nests.

Where's the hardware? This was undoubtedly leaking


The kid, desconstructing a door

Dented driver side inner

Rusty mirror mount, sanded down

Thursday, December 10, 2015

The part where I stumble into the secret handshake club


Condition Grover! We're going industrial, yo.
I learned a great deal of what I know about cars from Bill, the big brother of one of my best friends John in the old neighborhood. When I was working with Bill (as designated shop lackey!), he'd often send me on errands to pick up this thing and that, coating solvents, fabrication odds and ends, metal stock, a sky hook**, lunch, or whatever. Apart from sky hook hunts and lunch pickups, he'd send me to unadorned buildings hidden back in the light industrial section of Addison. These dimly-lit and often cluttered places would be occupied by people who would either accept that you belonged there by virtue of the fact that you found your way there on purpose, or who would challenge you immediately, since you weren't a familiar face. Bill would always give me a name to ask for however, and I was always supposed to drop his name to stand down the inquisition. I learned quickly some social engineering techniques- to always walk in like I owned the joint, since bewilderment could get you shut out.

Since I'm still relatively new in my town, I struck out to find the secret locations of the following vendors:
  • Welding gas and supplies
  • Automotive paints, coatings, and supplies
  • Steel, aluminum, and other metal stock
Here's the thing, I couldn't take the old approach, since Bill would normally write down exactly for what I should ask. This time, I had a fairly good idea, but I really wanted to leverage the knowledge  of the folks who, you know, know stuff because they're professionals. If I were to fake a level of expertise I really don't have, there's no way I could ask for help, or learn anything new (plus, as good a bullshitter as I pride myself on being, I suspect that they'd soon catch on). The old approach is OUT. I tried a new approach: Tell everyone the truth (GASP)! Here's how it went:

Met Mary of National Coating Supplies (NCS), who was hidden in plain view in north Urbana. I drove out and introduced myself. She liked my idea of taking body shop classes at community college, and told me that when we're ready to paint, she'll help us with supplies and advice. She also gave me a line on a welding gas supplier, who was hidden away in a different part of town. Wow, that went well. So far, so good.


R.J. Smith hooked us up - time to get at it!
Drove around the light industrial maze in east Urbana and found that welding gas supplier NCS Mary recommended, R.J. Smith- Walked in and met John. I let John know about the Mustang project, the new welding rig, my level of expertise (modestly described as an "advanced novice", or "have 2 community college classes under my belt, and know enough to be dangerous". Success! John had some solid advice, helped me figure out the correct wire to use on the Mustang floors (0.030"), and walked me through the process of getting a nice tank of Argon/CO2 shielding gas for the welder. I also picked up some tip gel and pliers. Great folks.

Finally, my co-worker Daniel informed me on the low-down that there is a steel material/stock warehouse in town called Kurland Steel Co. He described it as tricky to find, since it's not well labeled. Sounds familiar! After driving around it once and missing it completely, I saw in the middle of a large gravel lot a dark warehouse with a solitary man donning a heavy tan coat, kevlar gloves, and ballcap, all stained with oil, cutting a 16" I-beam with a behemoth of an industrial saw. This must be it. I wandered haltingly into the warehouse and was struck by the feeling that it might be an excellent place to film a post-apocalyptic industrial scene- it felt kind of Blade Runner-ish, maybe Terminator-ish, maybe Chuck-should-get-the-eff-out-ish. The gentleman running the saw kept on looking up at me with a puzzled look. After getting in within earshot, I stuttered and half-explained what I was doing. He kindly directed me to the office. The office was nice, potted plants and all. There sat the office manager named Kim. She looked up, also with the same puzzled look I got in the warehouse. They know I don't belong here. I managed to croak out an explanation of what I was doing, and what supplies I might require. Kim was patient; she did not roll her eyes I think, but I suspect she may have been slightly annoyed that A) I didn't know exactly what gauge and type of steel I wanted, and B) I didn't know "how this works" (and I totally didn't). Since I did have my welding cart plans on paper with me, improvised, and decided on the fly what I'd need, and in what quantities, she hung in there with me. At the end, she even gave me a suggestion on sourcing some good casters for my cart project. As scary as that was (first time, whee), I did get a slip to take back to the warehouse, where our original guy got me all set up: 24 feet of 1-inch square tube steel stock, and a 4' x 8' sheet of eighth-inch steel. He helped me carefully load it in my truck. I asked the warehouse worker his name and shook his hand. As he pressed his leathery hand into mine he said, "Grady, I've been working here for 37 years". I was glad to meet Grady. He's probably the guy who saves everyone at the end of the post-apocalyptic movie, probably by cutting the big bad in half with his bad-ass-as-hell saw.

What I learned:
  1. Social engineering may get you through some doors or past some obstacles, but if you want some help, you'd better stick to telling the truth.
  2. The secret handshake club is probably a myth. All of the people I met are normal, the apprehension I feel is just because it's all new to me.
  3. Most folks are happy to help you out. Hooray for humanity!

** On sky hooks: This is the runaround meant as a joke of course. There is no such thing as a sky hook after all. As much fun as Bill had with me, I think when I was in the service, I elevated this idea to a form of art unparalleled since- in addition to sending the uninitiated out to look for the legendary and storied "sky hook", we'd send guys on a hunt for some "shore line" or, if feeling ornery, up to the forecastle to get a "left-handed bosun's punch", which would result in a bruise in the recipient's arm after a burly anchor-chain hoisting boatswain's mate gave him a shot to the arm (or two, for flinching!). Ain't I a stinker?

Monday, December 7, 2015

Time to leverage some experts



Avacado and cucumber facial for this guy
After talking with many folks in town, and at car club (Illini Automotive Club), I drove the block and crank out to G&G Machine Shop in Rantoul and dropped them off for full treatment this afternoon: hot tank, magnaflux, hone and deck, bearings and freeze plugs, crank journal polish. If you're an engine block, this is like a spa vacation. You know, get all exfoliated, have a refreshing dunk, clean out those pores, get your bearings! The engine should come back all relaxed and renewed, smooth journals, stress-free, and all of it's worries massaged away. Brad from G&G will be our masseuse, er, machinist. He seems chill and knowledgeable, and had quite a few ideas and suggestions, all on which we'll capitalize. Excited to see what he can do!
Cranks gonna crank?