Polisher 1, Window 0

[HiHoAgRV]

I just finished making a replacement HEHR window and thought I'd hit the bench polisher real quick.

That didn't take long to ball up the entire frame when the polisher grabbed it. At least it wasn't a vintage unit, I can build another.

Be careful if you are gonna try to bench polish one of these things.

[Ganaraska]

Be careful is right, and always have the wheel going off the surface over the edge, never toward the edge. It can catch and ruin your part in an eye blink and might even throw it across the shop.

[Silverflames]

Ouch I feel for you. That's totally something I would do....

[Becky B.]

I tried the bench polisher once......that was it....it flung whatever I was polishing (can't remember--I block trauma out of my mind!) Sorry about your window--what a bummer! At least it didn't decapitate you!

[NJtoNC]

1st - wheres the thread on this replica window? I wanna see!
2nd - this does not belong to a 91 or a 63...

[HiHoAgRV]

Originally Posted by NJtoNC

1st - wheres the thread on this replica window? I wanna see!
2nd - this does not belong to a 91 or a 63...

Well, you are correct, it isn't for a 91 or a 63. I'm helping out a friend with a '55 and one window was missing.

Here is how a window starts life. Figuring out the blank is 1/2 the challenge, the bend sequence is super critical.

[reinergirl]

I need friends like you! Nice work... The window, not the polishing job

I've had that moment when I was polishing on of my overhead lights
Thankfully nothing Aerowood's roller couldn't get out

[NJtoNC]

id love to see more pics of the stages of the window. How will you replace the opening hardware? Will the window be fixed?

[HiHoAgRV]

Here are a few shots of the forming, as you can see I went ahead and made 2 frames...

I really only need the portion that opens on this project. I now will make the brackets that hold in the glass and cut out the opening for the glass. This will be for a crank open window and I'm still figgerin' up the center bar. The OEM versions use an extrusion that is NLA, I may mill one from bar stock. I have not been able to recreate the rolled hinge so a hidden piano hinge may have to be used.

For kicks and giggles I might go ahead and build the stationary frame for the spare window part that I just bent up.

[NJtoNC]

Neat-o. will you please post more as you proceed?

[Aviator]

Wow! I wish I had that capability.

[HiHoAgRV]

I cut out the opening with a nibbler and guide. It's an ugly way to do it but the best I have. A big file followed by scotch brite pads hides all of the ugly.

A few more steps and we will be ready to install it.

[Silverflames]

Very impressive!!

[Aerowood]

Nice work, I made a couple of those mid sixties hatches. It was fun. I also tried to make the rolled hinge also but was unable to do so. I believe they are roll formed. Nice brake

[desertair27]

Very nice! Too bad the buffer tore up the first one!

[HiHoAgRV]

Aero,
I also tried and failed on the hinge. I figured I could step bend it on the brake but had no luck with the 1/4 inside diameter. I may try rolling one.

I bent, cut and installed the clips(brackets?) the hold in the glass. Being hard headed I decided for another go at polishing. I bolted in a 1/8" piece of ply where the glass would normally be and then screwed the entire assembly to my work bench. A few passes with brown rouge followed by F7 and I finally got to the point where I started this thread.

[Lance M]

Awesome work Vernon.

[dirigible25]

Nice work HiHo!

I am in the process of building another street rod to go along with the one you can see in my avatar. I am cutting out various rusted out panels and forming new patch panels, some with concave surfaces. I can attest to your statement on the importance of bend sequence, it has to be well thought out before you begin.

Again nice work, and nice solution to bolting the new one down before polishing.

[wxbuoy]

Vernon, Nice work!

[HiHoAgRV]

Originally Posted by wxbuoy

Vernon, Nice work!

Hey Dave! I figure you are about to get iced in for the weekend. It's cold down here, windy and 33.

I need to be doing some stuff outside but just can't make myself.