fbama73
Contributor
Posts: 303
Age: 44
Loc: Indianapolis
Reg: 04-17-10
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05-11-12 09:02 PM - Post#2225022
Okay, the EMS cowl braces for my '51 are 70 bucks apiece. Now, nobody is going to prop up EMS parts more than I will- their stuff is AWESOME. But, as many of you know, it's a bit pricey.
The quality and the value are there, but on my recovering rustbucket, I added up the numbers, and found that I could spend over 2 grand just for parts that you never see when the car is done (cowl braces, driveshaft tunnel, front and rear floors, inner rockers, body braces) I'm building on a limited budget, so the more money I can save here, the more I'll have to spend elsewhere down the line.
I'm building a custom, not a concours restoration, so my parts don't have to be an exact duplicate of the factory pieces. They have to be strong, and look good under a coating of undercoat.
So, earlier this evening, the wife and daughter left to go grab us some grub. I decided to see what I could get done while they were gone. I'll list the tools used in each step.
The old brace was already removed. Pretty well toasted.
First, I made a paper pattern for the main part of the brace.
Using a unishear, I cut out the main parts from 16 gauge cold rolled.
Rolled the strengthening ridge in the pieces with a bead roller.
Put the main bend in with my brake. My brake is labelled as being for 20 gauge max, but it is what a po boy could afford, so I won't tell if you won't
I sliced back along the bend with a cutoff wheel in my 4" grinder, and also sliced through the bead so I could put the secondary bend in it. I made the secondary bend over a sawhorse with my cheapie slapper (made from an old wooden baseball bat) I bent a little bit at a time, taking it back to the car to check the fit. I also stopped working on the one for the other side, since the other side brace is stil in place, and I can't fit it at this point.
Bent the 1" channel in the brake for the vertical strengthening rib.
Then used the cutoff wheel to cut it to the 1/2" height
Notched it for the bend at the bottom, and for the taper at the top.
And got it tacked into place just as the wife and daughter pulled into the driveway with burgers.
Now, obviously, there is more work needed in finish welding and drilling holes, but I've got an hour's work in this, and probably have another hour left in welding and drilling
Also- this sure ain't gonna win you points at Pebble Beach. If you're looking for a 100 point retoration, this won't get it done.
But- it's as strong or stronger than the factory piece (especially since I used 16 ga) And- when the carpet and kick panels are in, it won't look a bit different than a factory piece.
There have been people in the past that have expressed interest in making their own braces. This shows you that it can be done with a bit of time and a couple of special tools. This probably isn't the best way to make your own, but it is an effective way. If it helps someone, then this post is worth it.
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cederholm
Frequent Contributor
Posts: 1309
Age: 46
Loc: Brooklyn NY
Reg: 09-28-10
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05-12-12 04:44 AM - Post#2225066
In response to fbama73
Well done and thanks for taking the time to post!!
- carl
Carl E. Cederholm
Brooklyn NYC
'53 Deluxe MoreDoor, triPPPle Rochesters, Fenton exhaust, dual Porter mufflers, 3" drop, 12v, and Offenhauser shinny bits! |
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Happy Belair
Contributor
Posts: 859
Reg: 10-29-06
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05-12-12 05:03 AM - Post#2225069
In response to cederholm
I agree, good handy man parts build.
See thats what makes this weekend sport so intresting..............the ingenuity used to rereate a long gone item and MAKE IT WORK.
Speaking of make it work.......that should be applied to me 
54 Belair 1067DTX, Roman red 327 Turbo350
54 Belair Hardtop, just bod off frame,work in progress
54 210 Station wagon Father in laws pass me down |
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 pm5471
"9th Year" Silver Supporting Member
Posts: 459
Loc: EauClaire,Wisconsin
Reg: 11-21-04
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05-12-12 05:24 AM - Post#2225078
In response to Happy Belair
Great work you are doing. Please keep the pics coming.
pete
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 rrausch
"12th Year" Silver Supporting Member
Posts: 9698
Loc: L.A, Cal. & St. Louis...
Reg: 04-07-03
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05-12-12 08:13 AM - Post#2225115
In response to pm5471
That is beautiful! It might not win points at Pebble Beach, but it sure wins points with us!! Great job! Can't wait to see it finished and in place and primed.
1953 210 Convertible, 261 with dual Carter YF 966S carbs, P.S., Remote Bendix P.B. Booster... shade-tree restoration about done.
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 Fitzback
"6th Year" Gold Supporting Member
Posts: 962
Loc: Qc. Canada
Reg: 01-23-08
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05-12-12 08:44 AM - Post#2225125
In response to rrausch
Very very good work , and save you a lot on parts to buy.
Fitz.
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fbama73
Contributor
Posts: 303
Age: 44
Loc: Indianapolis
Reg: 04-17-10
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05-12-12 05:27 PM - Post#2225249
In response to Fitzback
OK, l there it is all welded up. I won't drill it until it is in place. I've learned (the hard way) that you sometimes need some "fudge factor" built in, and waiting to drill is a way to gain that.
Since it won't show, I just used the squirt gun to weld it up. Usually, I tack with the MIG, then do my finish welding with the torch. It's a traditional custom, so I like to use the traditional techniques a bit. (It's gonna be a TRUE lead sled, too)
I appreciate the compliments and encouragement. Making the bottom of the car myself is saving me a bundle on the bodywork. By doing this myself, I'll wrap about 1500.00 in rust repair on the main shell, and that includes welding consumables and electricity.
I normally won't clog up the board with my fabrication exploits. I run the build blog, and figure that those interested can check things out there. But, for those who have any inclination, I want to show them that you can buy the tools (if you shop well) and materials to make these panels cheaper than you can buy the repop panels.
At the end of the day, it comes down to the question- "How much do you want to do yourself?" A question that, beautifully, has NO wrong answer. Me, I'm the kind of guy who wants to do as much myself as possible.
Heck, I bought an old commercial sewing machine last year, refurbished it over the Winter, and am curently working through the learning curve of using it. With luck, I'll be pretty decent by the time my car is ready for upholstery.
Edited by fbama73 on 05-12-12 05:28 PM. Reason for edit: No reason given.
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