Not much to show in the way of progress this week as went to a car hill climb event and spent some quality time with my wife. She has been painting inside the house nearly every weekend since January, so time for a bit of a break.
Hopefully I wont bore you with some set out photos for the chop.
You would think it would be easy marking out a 50 mm/2" section to remove to lower the front screen and roof down by. It is if perfectly vertical. But the front of the cab is not as has a compound curve right across the front as curving in both directions. Also the steepness changes as well which effects it again. It is steeper at each end compared to a shallower angle in the middle. So to get the same vertical drop evenly right across, the amount to cut out when measured flat along the steel face, will be less at the ends and more out of the middle. None of it will be 50 mm/2" as not vertical anywhere. I thought the easiest way to do it was use a laser level and spent time setting it up perfectly level and then levelled the cab with it.
You can see along the cab where I marked the top of the laser dot every 20 mm or so. To get the lower mark I simply held the ruler exactly vertical and with the top of the dot at 50 mm/2", then marked at the bottom of the ruler. Lowered the laser level until it lined up with the lower mark and repeated the marking for the bottom line.
Bit hard to see because you are fighting perspective here, but the lines are not parallel and get further apart in the middle compared to the steeper ends where it is closer together. Just got to see it as a right angled triangle. The sheet metal is the hypotenuse. As the angle changes, but keeping the same vertical height, the length of the hypotenuse alters. Ended up showing a 8 mm-5/16" difference between the middle and ends. That would have been a lot of extra grinding had I just ran some 2" tape along the front!
When it came to going around the corner, I will cut at the upper level line so I can stay above the change in angle from the lower vertical to the angled screen.
Unfortunately I can't cut all the way through the pillar at that height as would end up above the window sill around the back. It will have to be stepped down at one point.
To see where the best place to cut was I found it necessary to remove the welded in dash. Was quite a job getting it out as could not see the spot welds up under the dash holding it in or get a drill up in there anyway.
Can see a made a bit of a mess with the air chisel so this piece will need to be repaired or replaced.
Fortunately the damaged piece needed to be removed anyway so I could see the best way to cut a section out. Also this is the only way I would be able to weld it all back together again and get full welds on every face. As the outer skin wraps around this pillar on the outside creating two layers, there would be no way to weld the inner pillar face without cutting a piece of the body away or accessing it like this.
I have got some damage to repair as well as looks like a big gust of wind caught the door, or it was let go on a steep side angle at one point. It ripped the door stop attachment point clean out and then caused the tearing of the hinge hole and a long crease all the way down the panel. Access is going to be difficult as the pillar is in the way on the inside and only a small gap in-between.
The top of the roof has a bad section above the door opening too. I have decided to wait with cutting this cab apart until the other one is stripped as well and see if I can mix and match the best parts possible in the lengthening and widening process.
Another hack job found where a plate was held behind the hole and then arc welded and filled with bog. Want to weld shut this cowl seam anyway as its position does not line up with anything like the top of the guard or bottom edge of the bonnet. The very first year of production in 47, the year before my 48 cab, the factory did not have this seam. Not sure if the cowl was pressed as one or they joined it by another method or just leaded over it? Every cab from 48 on has this seam.