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> Green Hornet Progress Thread, Actually worked on it yesterday!
rick 918-S
post Jun 6 2010, 08:47 AM
Post #81


Hey nice rack! -Celette
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QUOTE(jmill @ Jun 4 2010, 08:39 AM) *

QUOTE(jasons @ Jun 3 2010, 11:19 PM) *

Good. I was wondering if you got it yet. Do you know what day it arrived in Milwaukee? Forward Air worked out great.


I showed up on the 2nd. I couldn't pick it up then because I had to coach soccer practice after work. Forward air did work out great. Your crate didn't even have a scratch on it. But the way you built it there was no way the motor would have been damaged anyhow. Their hub is only a few blocks from my work. I showed them my drivers license and they loaded the crate into the back of my pickup after I signed for it.

I'm stoked. I just need time now. With all the sports my kids are into I can't catch a free moment.


Ya, but those soccer games are a hoot! I remember my kids playing. They would stand on the field and chat right in the middle of the game.... Drove the parents nuts.

Any work on that fender yet?
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jmill
post Jun 7 2010, 07:56 PM
Post #82


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Haven't touched the fender. Just have time for late night parts searches. The wife has a long list of "honey do's." As soon as I get through a few of them I can work on the car. The fender is on the top of the list.
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jmill
post Jul 17 2010, 08:42 PM
Post #83


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The fender is finally going on. I had to take 4 days of vacation to get one day in the garage. It's funny how you plan to do all kinds of stuff on vacation and then life gets in the way. Some lady backed into the wifes BMW. There went one day chasing estimates and playing phone tag with insurance agents.

Anyhow, it's going on nice. Unfortunately the only rust free fender I had was dented up. After grinding off 1/2" of bondo and some work with a dolly block and hammer it looks pretty good. I'll have to bribe Rick to help me with the body work. I can weld and grind but I can't do bondo. It takes me like 5 coats to get things decent.



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jmill
post Jul 17 2010, 08:44 PM
Post #84


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one more.





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rick 918-S
post Jul 17 2010, 09:09 PM
Post #85


Hey nice rack! -Celette
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I could end up working over in Milwaukee later in the summer. The fender is looking good!
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jmill
post Jul 18 2010, 05:10 PM
Post #86


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Completed butt weld and then blended smooth.



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jmill
post Jul 18 2010, 05:12 PM
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All that work just to chop it out of there and add a flare. (IMG:style_emoticons/default/piratenanner.gif)



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jmill
post Jul 18 2010, 05:16 PM
Post #88


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From the backside. You can see the waves in the AA steel flare. It aint perfect but it beats glass.



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rick 918-S
post Jul 18 2010, 06:42 PM
Post #89


Hey nice rack! -Celette
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That butt welded seam came out so nice I bet you hated to have to cut it out! Get a body file from Eastwood or the Snap On, Mac, or your local tool guy. You should be able to file some of those wrinkles or waves out closer than they are.
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jmill
post Jul 18 2010, 07:00 PM
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QUOTE(rick 918-S @ Jul 18 2010, 07:42 PM) *

That butt welded seam came out so nice I bet you hated to have to cut it out!


Your not joking. I had to do so serious soul searching on that one. I sat in the garage for a 1/2 hour trying to figure out if I really wanted to do the flares. I came up with the fact that it was a bent up 1.7 destined to be cut up for parts. I saved it from that fate. The fact that this one is going to be on the road is a bonus. I went with the flares.

I tried to weld the flares on as careful as I butt welded the stock fender. I bought those Intergrips from Eastwood. I don't like them. The gap was too big and they didn't line up the panels flush. I tossed them over my shoulder. Any place that the two panels lined up perfect I spot welded. I then used deep throat vice grips, a dolly block and a hammer to line up the rest of the seam. I'm hoping when I grind off the weld it'll look as nice as the stock fender.

I can't see how guys weld flares on in a day. It took me several hours just to get one lined up right and tacked. I guess it gets easier with practice. (IMG:style_emoticons/default/confused24.gif)
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budman5201
post Jul 18 2010, 07:40 PM
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Looking Great man, keep up the good work!
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Drums66
post Jul 19 2010, 12:34 PM
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..You're doing a great job!(man,I sure miss kato-bLee) (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/smilie_pokal.gif)
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jmill
post Jul 25 2010, 02:29 PM
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Drivers side flare going on.



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jmill
post Jul 25 2010, 02:32 PM
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Going to need some more sanding disks and that body file. Does the body file remove material? I remember seeing a disk that heated up the metal and then you quenched it to shrink out the high spots.


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jmill
post Jul 25 2010, 02:40 PM
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QUOTE(budman5201 @ Jul 18 2010, 08:40 PM) *

Looking Great man, keep up the good work!


QUOTE(Drums66 @ Jul 19 2010, 01:34 PM) *

..You're doing a great job!(man,I sure miss kato-bLee) (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/smilie_pokal.gif)


Thanks guys, I'm trying. I'm not real happy with the flare symetry out of the box. They're close but not quite there. The drivers side rocker is also 3/4" shorter in the front. All you need to do is stand them next to one another and it's easy to see. QC isn't what it used to be.
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jmill
post Jul 25 2010, 02:56 PM
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Anybody use one of these and will it work on the waves?



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nomore9one4
post Jul 25 2010, 03:15 PM
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QUOTE(jmill @ Jul 25 2010, 01:40 PM) *

QUOTE(budman5201 @ Jul 18 2010, 08:40 PM) *

Looking Great man, keep up the good work!


QUOTE(Drums66 @ Jul 19 2010, 01:34 PM) *

..You're doing a great job!(man,I sure miss kato-bLee) (IMG:style_emoticons/default/smilie_pokal.gif) (IMG:style_emoticons/default/smilie_pokal.gif)


Thanks guys, I'm trying. I'm not real happy with the flare symetry out of the box. They're close but not quite there. The drivers side rocker is also 3/4" shorter in the front. All you need to do is stand them next to one another and it's easy to see. QC isn't what it used to be.



Very nice work...The rockers are different sizes because the factory originals where aswell. Dont know why but they where. (IMG:style_emoticons/default/smile.gif)
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jmill
post Jul 25 2010, 07:16 PM
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QUOTE(faux916 @ Jul 25 2010, 04:15 PM) *

Very nice work...The rockers are different sizes because the factory originals where aswell. Dont know why but they where. (IMG:style_emoticons/default/smile.gif)


I've heard that. I'd be fine with that if I picked up an original M471 GT.

At least I have an excuse if things don't turn out symetrical. I'll just say it came like that from the factory. (IMG:style_emoticons/default/rolleyes.gif)
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rick 918-S
post Jul 25 2010, 07:27 PM
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I've never used a shrinking disc. I've always wanted to try one.... just never bought one. and yes. The body file will remove material. Best to do some blocking before you start filing. if the waves are too high you could end up with a hole...Eeeek!
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strawman
post Jul 25 2010, 10:56 PM
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QUOTE(jmill @ Jul 25 2010, 01:56 PM) *

Anybody use one of these and will it work on the waves?


Yes, I've used one (though mine is smooth, not "corrugated" like the ones in the photo). It works pretty slick, though I'd advise you to go slowly. Don't try to work too large an area -- on my AA flares, I tried to hammer/dolly the waves as best as I could and then used the shrinking disk to isolate each wave separately. Fortunately, I got to practice on the 1969 Opel GT we're entering into the 24 Hours of Lemons on August 7 & 8 at Thunderhill... better that heap than my flared teener project!

Keep the photos coming!
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