Photo 19-1a thru 1d) Photos show my work
fabricating the right splash apron strengthener. Note how last photo in this
group shows the cut piece is bowed which is to be expected. The heat of cutting
bows the metal after which it must be worked and straightened (which I did).
Photo 19-2a thru 2b) There are always lots of little things to do along
the way, like cleaning threads.
Photo 19-4a thru 4d) Forming and initial trimming of right splash apron
for installation of strengthener.
Photo 19-5a thru 5dd) Photo shows my work on running board gussets. Each
gusset was previously cut, modified in its shape, and spot welded. Now with the
fitting complete, I am welding them solid. Note in second photo, I wrote down dimensions
before welding the gussets solid as reference in case the gussets warped during
welding. They are made of heavy metal, and with careful welding, did not warp.
Photo 19-6a thru 6d) I cleaned up areas
where running board gussets mounted to frame.
Photo 19-7a thru 7c) Here I am checking clearance
required for addition of splash apron strengthener and final trimming apron before
adding strengthener.
Photo 19-8a thru 8e) Here I am modifying center frame to running board gusset for clearance of splash apron and strengthener.
Photo 19-9a thru 9c) Here I am trimming bottom of running board to fit with splash apron and strengthener.
Photo 19-10a thru 10b) Checking my work for squareness and fit. Note that
bubble tilts slightly in such a way that water will run off of running board
away from car and not into car. I did both sides of car are like this.
Photo 19-11a) I used the old mounting holes between running board
and splash apron for spot welding the strengthener on the splash apron. This secured
the strengthener and at the same time filled the holes which had been mis-drilled
anyway, so it was like killing two birds with one stone. I then drilled new
mounting holes. So it worked out very well.
Photo 19-12a thru 12c) Here I am installing the strengthener to the splash
apron. Note I am welding with it clamped to a very heavy piece of angle iron.
This helps with two things. The heavy angle iron absorbs the heat and that
helps to keep warpage down. Plus the angle iron helps to hold the work straight
while welding. The piece still warped as to be expected, but not as much as it
otherwise would have, and I straightened it.
Photo 19-13a thru 13b) These are the new alignment holes for splash apron
and running board, first marked with panels assembled, then drilled with 1/8 inch holes
before welding the strengthener. In such a way, I could turn the apron over
after welding and have the holes as guides. Holes were then enlarged to ¼ inch
and apron was reinstalled to car.
Photo 19-14a) Here I am welding the braces inside the running board
solid. I previously had cut the braces free and reinstalled them to fit, but I
only tack welded them until all the work was done and I was certain I had
everything fitting right. Now I have welded them solid.
Photo 19-15a) This shows the bolts that hold the splash apron to
the front fender. The bolt holes were almost too far out of alignment, but
because they were close, and because these normally take elongated washers, I
elongated the holes just a bit which will hide and save a lot of work. I also
trimmed the apron here to be identical to the other side.
Photo 19-16a thru 16c) Here is the apron bolted to the running board. In the
bottom picture, note how the lip on the strengthener hides what would otherwise
be three edges (the running board, the running board cover, and the apron). So
instead of there being three edges there which could look a little ragged, they
all tuck into the lip of the strengthener which gives a very clean look. The
bolts do not have washers in photo because it is metal on metal but of course
after parts are painted washers will be required to keep from breaking the
paint.
Photo 19-17a thru 17d) Panels fit great!
Note: Other than a few minor things, very minor, the work of correcting the panel fit on right and left sides of car is complete. The right side required a particularly large amount of work and I wouldn’t have done it if the panels hadn’t been so terribly far off in fit. Before the corrective work, it took so much force to bend and bolt them together, it was just crazy. To fix the problem, I had to start at the frame and literally modify everything from the frame out. It was a huge job but now the panels fit perfectly and all the bolts and nuts go together easy as pie. On the one hand, I am so sorry that all this work had to be done. It was a correction of bad work that I had nothing to do with. On the other hand, I am so very happy to have it fixed and fixed right. No one will ever know from looking at the car that this work had to be done. Both sides now fit perfectly.
THANK YOU, JERRY!
