New Pro Stock tribute project

Show off your work! Anything from final results to full start-to-finish project journals.



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PostPosted: Fri Jan 15, 2021 2:39 pm
You can pick up a Big old Transformer machine pretty cheap now days as every one is going to the smaller Inverter machines. But the Old Transformers are BETTER machines!
Thats not just my opinion its a fact!
I still look for big old Miller Syncrowave and old Aerowave Machines and there are a couple Lincolns I also watch Craigslist for, I want one of these machines Bad!!!!!

The transformer machines are more rugged more well built and will last forever!
These new Inverter machines are all digital and like it or not Solid state when it works its nice but lets face it unless its made from Military grade parts Its junk its gonna stop working eventually and need parts and repair.

The day I was sold on Miller was the day when I was working at a bike shop the boss sent me out to go pick some parts at a welding supply store to pick up a part for his 30 year old Miller Transformer machine, They had the part in stock! No waiting on shipping it was their! it was available! we were back up and welding the same day! something to say about that in my opinion!

So ya I still have my old uglee Huge old Transformer machine and Ya I am still looking for my Holly Grail of a Transformer too! some day I will get one but till then I will keep my Transformer!
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Fri Jan 15, 2021 2:55 pm
Dont be afraid of the Newer Adhesives WHEN USED CORRECTLY these are a Great alternative to welding in my opinion others may disagree and I say too each their own but I like them, they have their place. Just like Mig Tig and Gas each has their place.
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Fri Jan 15, 2021 9:57 pm
Dennis,

Strap in I got busy tonight
Pictures will tell the story with some info
First >>> here is the welding locomotive in the corner of the shop

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I though I took a picture of the whole thing but I did not
It has to be about 4' x 5' x 3' on a huge cart
By the Model Number I bet you know what it is

Started about 4:00 this afternoon

I had the roof on and where I thought it should be
Said to myself >>> hey get on it and weld it in
So I got the three points that were dead on welded in

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the PS A-Pillar had a little blow through probably due to thin rusty metal there

Here is the worst part of the roof swap

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This has to get down to 35-5/8" to match the PS roof measurement

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First pass at attachment on the DS A-pillar

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If you note the little bump out of the metal in the other picture >>> I cut a relief in the corner and worked the metal into place with one of the favorite beating on tools in by cousin's shop

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Got it welded in and even used some old 1980 metal harvested from the hood of the donor car to reunite with the roof

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Sort of lost track uploading pictures, but here is the end result for the afternoons / evening's work

Left at 7:45 after drinking some cool ones for about 1/2 hr. marveling at the work done
:goodjob:
If I may say so myself

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Here is a mock-up of what I have planned for the flush mounted Lexan

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JT
Last edited by RamblerRacer on Fri Jan 15, 2021 10:08 pm, edited 1 time in total.



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PostPosted: Fri Jan 15, 2021 10:05 pm
I left out the one pic I wanted to show when I doubled up on another.

Here it is where I had harvested metal from the 1980 Firebird and used a sliver of metal to help fill in the gap.

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I tapped the edge of it around to the surface the windshield would rest on and welded that into place

JT



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PostPosted: Sat Jan 16, 2021 12:33 am
That welder isnt a Bad unit to start learning with!!!!
If I had been there I would have practiced with it a Bit and welded that stuff up for you with it. There is one on Ebay now for $1200 starting bid. That's an AC/DC machine it will weld Aluminum. Its got a built in Hi freq too so its made for Tig welding unlike my machine which is strictly a Power supply.
My Transformer machine I think may be bigger than that one lol Its like 4 feet long almost 3 feet wide and just as tall and almost as old!!!!
Thats a Good learner machine if you can get it cheap? I would jump on it If I were you!
After you learn you could flip it and buy a Nice machine.

Your Beads look good! I may have worked on fit up a Bit more but looks like there may have been some difference between the years of the parts used? so a slight miss match was there that looked like it couldn't be helped easily. Its a Race car not a show car!
You did a very good job you should be proud :goodjob:

Whats your Gas setting voltage and wire speed at? what wire are you using and what thickness is your wire????

I just went looking for my Pillar post repair pictures I cant find them :realmad:
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Sat Jan 16, 2021 8:17 am
The fit up was tough because to move the roof out of the way and put it back was taking a lot of time and difficult doing it by myself, so I decided to like I said chuck it on and tack the three corners that fit perfect without much help. You raise a good point and I said it in a post above, who knows how these things fit together from the factory.

Once tacked I used a sawsall and little panel cutting tool you mentioned in another thread and other cutting tools to nibble away at what was holding the roof high on the drivers side. I had to use a ratchet strap to pull the A-pillar down to match the angle of the one on the passenger side. You could see a huge difference eyeballing it compared to the sail panel using the fender bolt hole as a reference side to side. Once drawn into the right angle, I could wedge a piece of wood up enough to get the tools in to make the cuts. I’ll check on the wire and voltage settings. The one at the shop does have continuous settings vs a knob that clicks like the flux unit o have at home. I don’t go by what’s on the chart on the lid to the compartment where the spool is. For sheetmetal I start with the knobs at 9:00 and tweak up or down from there depending on the work. Last night I just started with them there and did not touch them other than bumping both up welding the inner parts where metal was doubled up.

The HF part of the TIG welder is the reason it does not get used much. Every time it got pulled out to use there was some issue to get the thing to work.

You raise a good point on adhesives as I am considering using that for the patch on the inner side of the sail panels. If not I plan to just tack patches into place and cover the area with one layer of fiberglass cloth to provide a smooth cover to paint gray like the rest of the interior surfaces. Depends on how far I get today, as I have a friend and his brother that I’m helping out with some repairs on one of their trucks. If I get to installing the patches I’ll tack them and cover them. If I don’t I may pick up some panel bond on Monday.

Have a good day and good luck with whatever is on your plate.

JT



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PostPosted: Sat Jan 16, 2021 11:31 am
RamblerRacer wrote:The HF part of the TIG welder is the reason it does not get used much. Every time it got pulled out to use there was some issue to get the thing to work.
JT


Its Probably the Spark Gap they need to be cleaned and gaped regularly. Its very simple to do.
Its easy to clean and adjust just remove them and clean contact points on a Piece of Sand paper like say 180 grit make sure they are flat and smooth. reinstall both and Gap to spec with feeler gauges tighten start welding.

They must be gaped to spec from the manual Miller has the manuals available for down load for free but you need your serial number. I tried to get it with just the Model # and they have changed the sight you have to do a search by serial number.

Here is the link: https://www.millerwelds.com/support/manuals-and-parts
You can even down load a parts manual for it on same page. You may want to buy new Contacts for it I am sure they are available from a Miller dealer and are only a few bucks IF they cant be cleaned up which I highly doubt they are really robust.

That is a Bad **** machine don't let its looks fool you!
Don't let the look of the controls fool you, You set these machines up for the foot control to control every thing. from starting amps to full amps only time you touch the front panel is to switch to AC for Aluminum. or to reverse polarity which when just learning don't fool with that. The manual will explain every thing about all the controls easy 5-10 min read. Its all about welding NOT reading.
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Wed Jan 20, 2021 9:33 pm
So a bit of a delayed update but here are some pictures and some info

Here is the monster sitting in the corner

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On Saturday I dug in and finished welding the roof in-place
I reinforced the a-pillar and welded in patches on the inside of the sail panels

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Then I blasted all the metal work with epoxy

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The last couple of nights I've been working on getting the balance of the cage done in white base
I did the last coat tonight and got it cleared as well.

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Thanks for looking

JT



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PostPosted: Thu Jan 21, 2021 10:20 am
Car is looking good.

Monster
Wow that thing has a Miller water cooler for it too that's nice! I wish I had one for my Monster, some day I will get one for it. I have one on my Lill green machine.
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Wed Jan 27, 2021 1:11 pm
Here are some pictures of the latest progress

I got the one piece nose off and supported on the lift in the center bay

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I also started on finishing up the interior with the "deck gray" to contrast to the white bar.
Just a cheap base with a matte clear
actually finished it up last night which is when I took these pictures

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Sunday nights I usually go to the shop to meet my cousin and clear out things so he can work on Monday
We set the nose and hood together >>> a taste of things to come.
The hood will get another 3 coats of clear once the blue stripe is painted

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Thanks for checking in
JT
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