Keyser Posted October 27, 2018 Share Posted October 27, 2018 (edited) Well Today is the day folks, going to start on the Pop build, first job is a little modification project to the Zed Shed II to make things easier for the build and then roll the Pop in and start staring at her and working out what I'm going to do I have been reading up on these builds and it appears that the first rule of Rod building is (no I'm not going to say that ) is there are no rules. I'm going to fully endorse this theory and fully intend to go my own way with this build with that in mind I'm going to try something a bit off the wall today. The next update may be a pile of scrap ready for recycling or it could be the first step in a great build - only time will tell! What are we building? A 1955 Ford 103E Popular Arrived like this - Stay tuned for updates Keyser Maximum Effort Edited March 4, 2020 by Keyser 7 Quote Link to comment Share on other sites More sharing options...
GMballistic Posted October 27, 2018 Share Posted October 27, 2018 Well that's something different, ...can't wait to see what you make of it. Good luck. 1 Quote Link to comment Share on other sites More sharing options...
grahamc Posted October 27, 2018 Share Posted October 27, 2018 In for the updates! Good luck with it! 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 27, 2018 Author Share Posted October 27, 2018 (edited) Evening all hope you had a fun Saturday So first Job was to start installing a modification to the Zed Shed II for the build I made This and this Forgot to take a pic of the other bit Anyway I then did something borderline dangerous Welded the bit I didn't take a pic of at the top of the Shed standing up there Even painted it white and This was welded and painted Then I painted the last bit Now that lot can dry and hopefully tomorrow I can put it all together and show you what it does aaannnnnd On with the build ........................ Edited October 27, 2018 by Keyser Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 27, 2018 Author Share Posted October 27, 2018 OK so I decided to try something a bit different with some bits I kept from a recently stripped Zed, The rear subframe mounting pins, removed the old metal and cleaned them up ran a die down the threads and checked they were all good then a bit of WTP weld through primer Point to note there is a metal plate behind the box section that the pin mounts in and its quite thick Add that to the 1.5 to 2mm mm or so of box and it is passing through about 9mm of steel in total. Next a piece of 60mm x 60mm 3mm wall box section Add holes in EXACTLY the right place checked the wall and it is near enough 3mm so I found this bit of steel in the scraps pile so 6 + 3 = 9mm the correct thickness, made some plates up and found that even though the pins are 20mm and I drilled a 20mm hole they don't fit see the gap? I checked the plate they came out of Ha its rebated So I countersunk mine Now it fits Remove 2 sections of box like so Clean the surfaces for welding WTP everything and find some spacers Sorted. More in just a mo. 1 Quote Link to comment Share on other sites More sharing options...
Andy_Muxlow Posted October 27, 2018 Share Posted October 27, 2018 Great start buddy. Keep it up 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 27, 2018 Author Share Posted October 27, 2018 Got out the big boy welder again Few spot welds Ok a lot of spot welds but I didn't want it to move! Then I welded it all up solid Hmm I was having problems seeing what I was welding??? Still a bit extra won't hurt I definitely got good penetration as the bottom looks like this Then I worked out why I couldn't see what I was doing Its called a "cheat" its a magnifying glass that clips into the mask for old gits like me who can't see any more, I only need it close up so I took it out when I was welding the bits to the roof earlier Moving swiftly on - WTP everything again Then put the previously removed sections back on and weld them in place Welding is so much easier when you can SEE!!! The end result we have That's a lot of work for one bar to be honest More in a mo ....................... 2 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 27, 2018 Author Share Posted October 27, 2018 For my next trick I require 2 x 80mm diameter steel circles about 8-9mm thick but I don't have any. But if I scribe 2 circles on here its 1cm thick plate cut it out drill a hole Stick a bolt in it weld the bolt on and put it in the lathe I can do this O I skimmed it as well add a 20mm countersunk hole a pin That will go here So first job tomorrow is make another one Have a great evening. Keyser Maximum Effort 6 Quote Link to comment Share on other sites More sharing options...
grahamc Posted October 28, 2018 Share Posted October 28, 2018 WOW - someone has been busy 1 Quote Link to comment Share on other sites More sharing options...
andy james Posted October 28, 2018 Share Posted October 28, 2018 Great skills mate. 1 Quote Link to comment Share on other sites More sharing options...
The Bounty Bar Kid Posted October 28, 2018 Share Posted October 28, 2018 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted October 28, 2018 Share Posted October 28, 2018 The car doesn't appeal to me but but your skills and can do attitude are awesome 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 28, 2018 Author Share Posted October 28, 2018 3 hours ago, andybp said: The car doesn't appeal to me but but your skills and can do attitude are awesome Cheers mate, we can’t all have the same taste it would be boring but this is a big project and some new challenges. I’m enjoying it so far but it’s gonna be slow as I have to make everything from scratch with no plans and no idea what each bit will need or be until I get to it 1 Quote Link to comment Share on other sites More sharing options...
ATTAK Z Posted October 28, 2018 Share Posted October 28, 2018 Pah !!! ... I can do all that ... Seriously I wish you were closer so I could watch you at work and learn ... amazing skilzzz If there's another world war I'd like to be on your side please 1 Quote Link to comment Share on other sites More sharing options...
andybp Posted October 28, 2018 Share Posted October 28, 2018 38 minutes ago, Keyser said: Cheers mate, we can’t all have the same taste it would be boring but this is a big project and some new challenges. I’m enjoying it so far but it’s gonna be slow as I have to make everything from scratch with no plans and no idea what each bit will need or be until I get to it from scratch ,no plan no idea that sums me up 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 29, 2018 Author Share Posted October 29, 2018 I'm back Sunday morning and I finished that mod now all the paint is dry Bolted all the bits together to give me .................. The black rope is a safety/tie off line in case anything needs to stay lifted, unlikely but possible. Load test ...... Last time I did a big project I had @buster for heavy lifting now I'm on my own I have to keep calling the wife and kids to lift things, given that the Pop will need the body lifted on and off the chassis multiple times and engines and suspension subframes are heavy this is my solution to one man working, hope you approve Keyser 3 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 29, 2018 Author Share Posted October 29, 2018 Back to the Pop, Now I have my hoist the first job was to get everything level and square so I have a base point to work from, so after much faffing with shims and wedges I got the subframe level - "Make The Noise" - It's didn't but I have never had a level that did Finished making the other plate, welded up ready Now I took some measurements and did some thinking and realised that the spring hangers were going to be an issue, I kept the original and was going to reuse it Yer, don't really want to reuse that! it is also not strong enough as it is welded to a reinforced section under the Zed, my rear subframe mount is only 60mm wide meaning I have to support the overhang and this is going to be a high load point. Solution ....... Coffee, Head scratch, More coffee, eureka moment well not really I just decided I'd have to make my own but much stronger. So same piece of plate and method I used for the front pins They look the same but are 144mm across Then I made 2 strips out of some 1.2mm steel folded the edge and punched some holes Great aren't they?? Anyway weld them together Flip and hammer round(ish) cut a length of this bit of pipe which happens to fit in the rubber mount weld round the inside of the lip and weld the insert in the middle test Happy Repeat steps above Clean up and primer Told you this build was gonna be slow!!!!!!!!!! About 5 hours to make the second pin carrier and both spring tops, I'm not complaining I'm having fun but this will be a long project. More in just a moment 4 Quote Link to comment Share on other sites More sharing options...
OranginaZ Posted October 29, 2018 Share Posted October 29, 2018 Awesome, what a brilliant start to your project. Looking forward to following this build. Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 29, 2018 Author Share Posted October 29, 2018 (edited) This next bit is quite boring, it took the rest of the day and doesn't look much but it took ages to get everything lined up, square and welded. I even had to cut one side off and re-do it after I found a 1.5cm discrepancy in the subframe rails front to back on the first attempt! Lots of this this and this going on Ended up with a completed hangar though which fits like so The over length bars to the rear are there until I work out how far back I need them to meet the back of the body, easier to cut down than extend Next job is to fit the spring carriers, the shocks may get mounted into the wheel arch that has not been decided yet I will need to look at the fitment and line up. Of course this is just the basic carrier it will need gussets and cross bracing for strength it may also need some reworking so no point in finishing all the strengthening and then have to change it again later - little steps Stay tuned chassis rails should arrive this week so I can make some more next weekend hope to get a couple of evening in and do the spring hangars during the week though Keyser Maximum Effort Edit: After I re-did the rails the discrepancy was down to 0.25mm give or take a mm Edited October 29, 2018 by Keyser 2 Quote Link to comment Share on other sites More sharing options...
buster Posted October 29, 2018 Share Posted October 29, 2018 awesome bro. 1 Quote Link to comment Share on other sites More sharing options...
Beb Posted October 29, 2018 Share Posted October 29, 2018 Thought I was reading a whole week's worth of updates.... All that since Saturday? 1 Quote Link to comment Share on other sites More sharing options...
Paul K Posted October 29, 2018 Share Posted October 29, 2018 Nice work.... 1 Quote Link to comment Share on other sites More sharing options...
Keyser Posted October 30, 2018 Author Share Posted October 30, 2018 (edited) Small update - Chassis rails arrived That should take the weight and the power nicely I jest of course they are the beams to make my new chassis table with, but I only had a couple of hours on it tonight and it took that long to get it square and level!! How many spirit levels do you have? That's most of my collection I'll get this built befor I do anything else though Edited October 30, 2018 by Keyser 2 Quote Link to comment Share on other sites More sharing options...
scobie140 Posted October 31, 2018 Share Posted October 31, 2018 I don't know if i'm impressed more by the build or that you have so many spirit levels 1 Quote Link to comment Share on other sites More sharing options...
veeg33 Posted October 31, 2018 Share Posted October 31, 2018 Can someone please work with Keyser and start a YouTube channel about this build??? This is awesome!! 1 Quote Link to comment Share on other sites More sharing options...
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