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Old 10-08-2014, 03:06 PM   #1387
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Here went #2.. I believe this is passenger side...







Done, and put away for later fitting...
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Old 10-08-2014, 03:21 PM   #1388
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Moved on to headlamp door.
Managed to break the window in my media cabinet while rotating this big lump...


Even had to blast the backside as it was full of dirt and corrosion.


I have decided that I will not be doing rivets to reattach it to the outer skin as OEM... I think I will drill and tap so I can remove it later for repolishing.


After dressing and blasting the casting, the front side is full of casting marks and pits. I did some blend work, but realized its never gonna be smooth.
I sat and looked at it for a bit... and realized I could set to it with a grinder, sand, blend, and buff, and polish the whole thing.

Then gave myself a back hand to the side of my head... stupid boy.

I might have to go with a wrinkle semi-gloss black powder, for the as cast areas, or risk it looking crap...
Gotta think about this
..
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Old 10-08-2014, 06:44 PM   #1389
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What about filler, primer and Mercedes silver paint?
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Old 10-09-2014, 01:28 PM   #1390
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What about filler, primer and Mercedes silver paint?
I did some test pieces in silver metallic powder, and it just did not "Pop" for me...
I have seen these castings painted one color too... not for me...

So, here we go...

Prepped and ready... had pre-conditioned casting at 500deg for 30 mins to try to outgas and burn of impurities... common suggestion when doing this type of piece... it was smoking alright!


Laid down a pretty thick coat of gloss black powder.


Getting this thing into my oven was a tight squeeze... I did 2x prep/positioning runs beforehand... only about 1/4" clearance all around!


Took almost 30 mins for casting to get to 400f and the powder to flow out... thise things have a lot of mass! Then another 30 mins to cure.

About 2 hours later, it had cooled enough to take it out... with welding gloves on!


Having had my previous experience with the futility of getting a good shine on these castings, I am going to bring the highlight areas to a brush finish... I think the contrast with the black and polished surfaces is good.

Almost done... just a little flow work on the radiused sections.
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Old 10-09-2014, 02:15 PM   #1391
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Nice!!


Sent from my iPhone using Airstream Forums
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Old 07-09-2015, 12:40 PM   #1392
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Really... 9 months since I last posted?

Its been a rough year... with so much going on and indeed going wrong...

My 99.9% finished Alfa got damaged in a freak garage accident... my 1000lb tall toolbox drawers lock failed, allowing the drawers to roll out and tip over.... with my luck recently, the only miracle was I was not near it when it happened!
On top of that, every single family vehicle has broken down and needed or needs something...
Top that with a sprinkling of personal and family health issues, my girlfriends 2x broken wrists, my ongoing eyesight issues, and the sudden, crushing and unfathomable suicide of a close family friend..
Then just when we thought things were looking up, we had a slab leak in the house... which meant ripping out the floors and drywall up to about 18".... AGAIN. I elected to do that myself, and the results were good and indeed good for me, as it got me motivated.
Acacia Engineered Hardwood!
The best news is that I have enough to do the Airstream!



The floors are finished, and hope to have the Alfa out of my hair in a week or so, and the son's Subaru is next, but it just looks like a headgasket. The GF's Range Rover will need a new Viscous Coupling put in the Transfer Case, and that is ordered.

Despite all this, the tools and parts for the next step on the Airstream are amassing... and just we snuck a trip to Costa Rica in to relax... which was awesome!





Anyway... I'll be back!
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Old 07-09-2015, 12:53 PM   #1393
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Welcome back Steve!
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Old 07-09-2015, 04:59 PM   #1394
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Anyway... I'll be back!
Wow, I sure would hate to have him chomp on one of my fingers!

Welcome BACK!
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Old 07-10-2015, 11:19 AM   #1395
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Thanks Guys!

Actually, his name is Pepe, and he was super gentle!
He pecked at my fingers several times, and hopped all over us, and was not a worry a worry at all!


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Old 07-10-2015, 06:05 PM   #1396
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Are those the natural beak colors or did someone paint those on there?!

I know nature can be pretty colorful but the colors on that beak are amazing
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Old 07-11-2015, 12:53 AM   #1397
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I know Brad, he was stunning. FYI, the pictures were taken with my Droid phone and uploaded completely untouched. Amazing!
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Old 07-11-2015, 07:02 PM   #1398
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Welcome back! I think we all understand the expression 'Life Happens!' I can't think of a single post stating that someone did something in less time or for less money than they originally thought it would take. Myself, I am three years into a 6 month project with no end in site. As long as we never give up it will eventually get done.
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Old 07-11-2015, 10:36 PM   #1399
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Welcome home Steve. Glad to see you back!

Charly.
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Old 07-15-2015, 12:41 PM   #1400
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Thanks Charly, its good to be back, if not quite "Back at it yet"...

As I stated before, the actual progress stopped, but parts collection did not!

One thing which falls squarely into the "maybe" category is this hunk of granite and matching tiles that a neighbor gave me...




I would LOVE to replace the kitchen counter with this, but the darned thing feels like 100lb!
Its 50" long, and way too deep(wide?), but maybe with the it cut to size, and a sink cutout, it would work...
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