 Fixing the rocker covers, Saving them from cancer |
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| DNHunt |
 Dec 14 2007, 10:09 PM
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#1
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914 Wizard? No way. I got too much to learn.  Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598  |
Here's what I started with. Rust in the area under the opening for the jack plate.
 Because there are some compound curves I decided to fill a small amount with welding and cut the rusty metal from the flatter area.  |
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Replies(1 - 10)
| DNHunt |
Dec 14 2007, 10:13 PM
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#2
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
I cut out the bad metal.
 Then I bent and hammered a replacement piece. I just tacked it tonight and I'll finish welding and grinding tomorrow.  Dave |
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| McMark |
Dec 14 2007, 11:17 PM
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#3
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914 Freak! Group: Retired Admin Posts: 20,179 Joined: 13-March 03 From: Grand Rapids, MI Member No.: 419 Region Association: None |
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| DNHunt |
Dec 15 2007, 09:12 AM
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#4
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
Finished 1 side, at least it's ready for primer and filler.
 Inside  Dave |
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| Gint |
Dec 15 2007, 09:34 AM
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#5
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Mike Ginter Group: Admin Posts: 16,084 Joined: 26-December 02 From: Denver CO. Member No.: 20 Region Association: Rocky Mountains  |
You're getting pretty good at that Dave.
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| DNHunt |
Dec 15 2007, 11:10 AM
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#6
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
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.  I then started making the repair piece. First I bent the bottom edge using the vice hammer and wooden block.  |
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| DNHunt |
Dec 15 2007, 11:15 AM
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#7
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
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.
 Then I transferred the curve for the corner onto the patch by tracing it with a pencil. I added enough for the stengthening bead.  |
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| DNHunt |
Dec 15 2007, 11:22 AM
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#8
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
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.  And the outer radius  |
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| DNHunt |
Dec 15 2007, 11:24 AM
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#9
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
This is what you end up with to be welded in.
 Dave |
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| rhodyguy |
Dec 16 2007, 11:06 AM
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#10
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Chimp Sanctuary NW. Check it out. Group: Members Posts: 22,098 Joined: 2-March 03 From: Orion's Bell. The BELL! Member No.: 378 Region Association: Galt's Gulch |
nice work dave.
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| DNHunt |
Dec 16 2007, 09:43 PM
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#11
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914 Wizard? No way. I got too much to learn. Group: Members Posts: 4,099 Joined: 21-April 03 From: Gig Harbor, WA Member No.: 598 |
Homemade paint booth in an unused greenhouse
 Plenty of ventilation with the fans  Here's the primer sprayed on  |
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