Chasing rust again

[Angry_Truck]

It has been a slow summer as far as working on my truck goes. I finally got around to looking at the front grill and found the rust monster spared no part of my truck. It also looks like there was some damage from where the PO installed aftermarket turn signals.
BEFORE:


AFTER (mocked into position):


Chasing rust around this truck has definately helped my fab skills - it only took 1 try to get this close. I only hope I am as lucky with the other side.

-Brian (and Angry)

[Mikel]

Very nice!

[brute4c]

WOW!! Wish I had half your skill!

[jpsnblood]

Very nice.
It never ceases to amaze me at the level of skill and accomplishment that exist in our small circle.
Your restoration and many other of our members are of the highest quality.
It encourages me to try to do a more thorough job on my junk.
But if I get a chance to get back to the mountains.I will beat the stew out of what ever I got.
Great job, want more pics and detailed info on exactly how you did it.

[Angry_Truck]

Thanks.
Sorry, I didn't really document the process well but, here are some more pics.

Fortunately, the original was in decent enough shape to make a pattern out of paper:


The part was originally made out of 2 pieces- the main sheet and the box that goes around the cut out for the light.
Here they are seperated:


Here they are mocked into place:


Once I had the two pieces roughly in the right spot, I welded them together and the ground the weld down to a smooth radiused edge.

The hard part is getting the bends in the right place (thats what the marker lines are for) because I don't have any special tools like a brake. Just a vice, some various diameter pipes, and a hammer.

-Brian (and Angry)

[syzygy]

The hard part is getting the bends in the right place (thats what the marker lines are for) because I don't have any special tools like a brake. Just a vice, some various diameter pipes, and a hammer.

You did all that with a vice, some pipes, and a hammer? You give me hope that I, too, can do awesome repairs without buying tons of equipment I can't afford...

[Mikel]

Gorgeous. I love seeing such quality work done with simple tools.

Thanks.
Sorry, I didn't really document the process well but, here are some more pics.

Fortunately, the original was in decent enough shape to make a pattern out of paper:


The part was originally made out of 2 pieces- the main sheet and the box that goes around the cut out for the light.
Here they are seperated:


Here they are mocked into place:


Once I had the two pieces roughly in the right spot, I welded them together and the ground the weld down to a smooth radiused edge.

The hard part is getting the bends in the right place (thats what the marker lines are for) because I don't have any special tools like a brake. Just a vice, some various diameter pipes, and a hammer.

-Brian (and Angry)

[ryanroo]

that is quite impressive. excellent work
Ryan

[SAC715]

Just think if you had all the tools, you could be making new door skins and etc with your skills.

[randyscycle]

Nice work indeed!

Its amazing what a little ingenuity, and persistence can produce.