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914World.com _ 914World Garage _ Fixing the rocker covers

Posted by: DNHunt Dec 14 2007, 10:09 PM

Here's what I started with. Rust in the area under the opening for the jack plate.

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Because there are some compound curves I decided to fill a small amount with welding and cut the rusty metal from the flatter area.

Posted by: DNHunt Dec 14 2007, 10:13 PM

I cut out the bad metal.

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Then I bent and hammered a replacement piece. I just tacked it tonight and I'll finish welding and grinding tomorrow.

Dave

Posted by: McMark Dec 14 2007, 11:17 PM

Nice Dave!!!

Posted by: DNHunt Dec 15 2007, 09:12 AM

Finished 1 side, at least it's ready for primer and filler.

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Inside

Dave

Posted by: Gint Dec 15 2007, 09:34 AM

You're getting pretty good at that Dave.

Posted by: DNHunt Dec 15 2007, 11:10 AM

Here's how I did it. I used a vice, a piece of 2X4 with 1 edge radiused to the curve at the bottom edge of the rocker cover, a piece of 1" galvanized pipe a ball peen hammer, my wire feed welder ad a grinder.

First I filled in a small area that was pitted. I didn't want to deal with compound curves if possible. I ground that down.

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I then started making the repair piece. First I bent the bottom edge using the vice hammer and wooden block.

Posted by: DNHunt Dec 15 2007, 11:15 AM

Then I measured from the center of that bend on the rocker cover to the bead on the edge. I transferred that to the ptch and bent that edge over the vice with the hammer.

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Then I transferred the curve for the corner onto the patch by tracing it with a pencil. I added enough for the stengthening bead.

Posted by: DNHunt Dec 15 2007, 11:22 AM

I cut the patch to length and added the mounting hole.

I cut out the area for the curves then used the galvanized pie and the hammer to shape the patch. This is the inner radius.

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And the outer radius

Posted by: DNHunt Dec 15 2007, 11:24 AM

This is what you end up with to be welded in.

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Dave

Posted by: rhodyguy Dec 16 2007, 11:06 AM

nice work dave.

Posted by: DNHunt Dec 16 2007, 09:43 PM

Homemade paint booth in an unused greenhouse

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Plenty of ventilation with the fans

Here's the primer sprayed on