The Porsche door is back again and the work with the Opel roof panel continues.

The trip from the paint shop to the sign maker expose a new kind of skills. Cutting out and fitting the letters are a job which is dependent on a sure eye. The work can be seen at Image 1 and the result at Image 2.

Image 1 The text is cut out of self adhesive material.
Image 2 The police car door is ready for delivery.

The work with the Opel roof continued with the preparing work with the welding flanges on both the roof and the body. During that work a small rust hole was discovered and repaired. NOS means new old stock or parts not sold yet. The parts is usually painted with a simple and cheap primer for basic rust protection during stock holding but sometimes not painted at all. When buying NOS part the condition must be controlled, the store standard is important. The preparing of the welding areas was done with the help of strip discs, Images 3 and 4.Image 4 show the underside of the rain channel, the surrounding painted area was covered by protection tape, see chapter 5 in the book. In Image 3 the rusty surface, from storing in moisture, can be seen. After cleaning of both sides of all welding areas the bare metal surface was painted with welding primer, Image 5. See also chapter 5 in the book.

Image 3 Cleaning the welding flange by a strip disc. Note the surface rust from many years of moisture exposure.
Image 4 Removing the drip channel from paint. Note the protecting tape under the strip disc.
Image 5 All clean areas was painted with welding primer.

During that work some small dents was discovered, Image 6. The small in indentations was easily aligned with the hammer described earlier and a plastic dolly, Image 7. With all preparations made, a visitor was helpful when the panel was lifted up to the body, Image 8. After some adjustments of the position the panel was clamped in the rain channel with the converted welding clamps described earlier, Image 9. Note the small piece of 2 mm thick sheet under the foot of the clamp. With help of this small piece of sheet the measure in Image 10 was kept under control during the resistance welding process.

Image 6 A small dent.
Image 7 The tools used for removing the dents.
Image 8 The roof was lifted up on top of the car.
Image 9 Clamping of the side of the roof to the drip channel.
Image 10 Cut away view of the drip channel.

The width of the drain channel was smaller than the diameter of the copper electrode, Image 11. After shaping the electrode as in the image the electrode could be used. Image 12 illustrates the small distance between the electrode and the drain channel, approximately 0.5 mm. During the welding work the lower electrode was used with a shoe, see Image 13 and chapter 6.

Image 11 The shape of the welding electrode for the drip channel.
Image 12 Welding electrode in the drip channel.
Image 13 Resistance welding of the roof sides. Note the electrode shoe.

At the front and rear welding flanges, standard electrode was used, Image 14. For better result the electrode should be made from a special copper alloy, M 328, developed by an American company, Mallory. See the book and chapter 6 for DIN and EN standards for the electrode material.

Image 15 shows the car with the new roof.

Image 14 Welding with conventional electrodes.
Image 15 The car with a new roof panel waiting for transport to the paint shop.

Panel Beating Doctor Bengt Blad

At this point in my life when I was about three quarters through the medical schooI I discovered the English wheel and the Eckold machine, and, one thing leading to another - no more time for med school.

More about the book

This book, with around 1,500 pages of reader-friendly text and about as many illustrations, is a summary of 40 years of working with vintage, collectors' and racing cars.

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