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Old 02-03-2013, 03:12 PM   #1181
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Almost done...
Just a little more painting to do...



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Old 02-03-2013, 05:12 PM   #1182
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Steve,

The grill looks fantastic! Do you plan on applying a clear coat to preserve that finish. I ended up painting mine black for the time being; skeptical that the cast metal would hold a shine for long. That alloy is definitely not "aircraft grade".

Charly
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Old 02-03-2013, 05:14 PM   #1183
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Old 02-04-2013, 11:09 AM   #1184
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Thanks Peeps!

Charly, I agree that the castings are not the best... the badges I did last year are already dulling...
The issue is, do I coat and protect it for a while, then have strip and recoat, or just keep touching up the polish???

Actually, I have to say that the grill was not a tricky project... just elbow grease really.

Now onto bigger things...
This week, I want to glue the center grill fairing back together, and try to figure out how this whole LH, RH and center section and spoiler is gonna play.

The 3 pieces lap(joggle) together, and the upper part of the center has a curved aluminum stiffening bar, seen here, which bridges it all together.


The plan for now is:
1/ Cut off the front leveler mounts.
2/ Bridge a piece of 6x2 across the front crossmember and secure both of the front corner fairing to it.
3/ Remove both front fairings and the wood as an assembly. This will hold them in thier mounted positions.
4/ At home, fix any cracks or deformity, then mount the repaired center section.
5/ Do the mods and build a mould of the whole thing...

Did this for 30 years... Hope I have not lost my touch!

Big piece... so gotta get my kids Jeep outta my garage first tho... thats priority!
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Old 02-06-2013, 02:03 AM   #1185
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Practice Aluminum Mig welding..

Unwanted holes in the broken and hacked together rear bumper...

Begone!

Backed them with some copper plate..



First try was a little blobby...
Had to file it off..


Then re welded them...
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Old 02-06-2013, 02:16 AM   #1186
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Then I got crazy...

Filed and flatted out...



Then it was time....

I spent maybe 2 hours putting a V in the two halves of the rear bumper and cleaning ready for the joining...
Set it up on the bench, and checked and adjusted it until it was about as good as it could be..




Then I went for it...
Please understand, I aside from a quick test, I have never Mig welded Aluminum before...

I fiddled with the setting, and tacked it in place.
Then I laid down a heavy if ugly bead... or three!
Also filled the holes on the other half of the bumper.


And the back...

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Old 02-06-2013, 02:18 AM   #1187
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About an hour with a file, and I have this...
Still some work to do, but its looking better...


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Old 02-06-2013, 06:47 AM   #1188
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Very nice! I've always wanted to try aluminum welding but never have taken the time to try.

What spool gun are you using?

Brad
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Old 02-06-2013, 09:54 AM   #1189
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If your welding doesn't work out I have bumper that should fit
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Old 02-07-2013, 01:27 AM   #1190
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Thanks Brad...
This is the spoolgun I have..
http://buy.snapon.com/catalog/item.asp?search=true&item_ID=636204&PartNo=MHG5B&g roup_id=675736&supersede=&store=snapon-store&tool=all



Lots of work done... but I am realizing that it might never be right... It was a pig to line up because it was tweaked twice...
Trying to work out how to ship a 80" Bumper is a pain... but maybe the best option, thanks John!


But because I am sick in the head...
I wanted to see...





The bumper face would be a 5' job, but the top face is a rippled mess..
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Old 02-07-2013, 02:04 AM   #1191
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Steve,
Did you use a hammer drill to get the bumper retaining screws removed?
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Old 02-07-2013, 11:55 PM   #1192
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Quote:
Originally Posted by crazeevw View Post
Steve,
Did you use a hammer drill to get the bumper retaining screws removed?

Only the front has those recessed cross head screws, and I could not shift them at storage, so I removed the bumper with the brackets.
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Old 02-08-2013, 01:15 AM   #1193
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Quote:
Originally Posted by shepherd57 View Post
If your welding doesn't work out I have bumper that should fit
Any chance you have the bumperettes off the rear bumper?
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Old 02-10-2013, 04:52 PM   #1194
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Quote:
Originally Posted by Keyair View Post
Thanks Brad...
This is the spoolgun I have..
I don't think that gun will fit my welder. I have an older Hobart 200 amp mig welder. I guess I need to get serious and find a spool gun for it!

Quote:
Lots of work done... but I am realizing that it might never be right... It was a pig to line up because it was tweaked twice...
Trying to work out how to ship a 80" Bumper is a pain... but maybe the best option, thanks John!
Steve,

I should be seeing John sometime in the next 2 to 4 months. It might be cheaper shipping for me to pick it up John and then ship it from Kentucky. I don't know how customs is going to deal with a bunch of motorhome parts crossing the border but it might be worth looking into.

Brad
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Old 02-10-2013, 09:54 PM   #1195
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Yup, John and I have a plan in principal!

Today I removed the headlamp surrounds for refinishing...

Drilled out the multiple




Ready for some elbow grease on the bench!
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Old 02-10-2013, 09:59 PM   #1196
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Steering wheel replacement!

Old...


Like for like!
I am so STOKED!


Done!
Might get some SS button head screws later...
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Old 02-11-2013, 12:38 AM   #1197
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Leaks...

Pulling my HVAC cover for WXboy...

Front floor is wet... and rotten...


As is the HVAC cover corner...


Spent a couple of hours raking out sealant at the top of windshield, and then pumped Tempro into the gap...
Lets see if that works!

Oh,,, also a good heads up...
Put a smal screwdriver into the lower edge of the windhield centerbar lockstrip...
Look at this!

Gusher... it was full of water under there!



This was all in there...
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Old 02-11-2013, 06:20 AM   #1198
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Quote:
Originally Posted by Keyair View Post
Pulling my HVAC cover for WXboy...

Front floor is wet... and rotten...

As is the HVAC cover corner...

Spent a couple of hours raking out sealant at the top of windshield, and then pumped Tempro into the gap...
Lets see if that works!

Oh,,, also a good heads up...
Put a smal screwdriver into the lower edge of the windhield centerbar lockstrip...
Look at this!

Gusher... it was full of water under there!

This was all in there...
Thanks! They seem identical..... So i have no idea what the hold up us.
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Old 02-14-2013, 11:21 PM   #1199
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Pass side Headlamp casting done...


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Old 02-15-2013, 12:08 AM   #1200
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can't wait to see the before and after pix of your grill Steve!
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