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ST4 back from the dead

Puckle

Well-known member
SUPER Site Supporter
Thanks for the kind words guys, glad you like it.
A bit more progress today, I have made the side windows and the angle iron frames for the top of the windscreen - I bent the radius around a suitable sized pulley using lots of heat.
I have also started on the most difficult panel, the front roof section - this has compound curves to be fabricated, again I've found hammering it around the domed head of a nitrogen gas bottle seems to be about the right profile.
 

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Puckle

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Had to do a couple of other jobs so work on Snow-Trac delayed but managed to get cab finished and start on front slam plate.
 

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Puckle

Well-known member
SUPER Site Supporter
Finished the slam plate, had to straighten the bumper brackets and make new bumper to ensure everything lined up correctly first.
Also been making new fuel tank - I know many people don't like it inside the cabin so I will cut the floor round it and make a partition wall so it is sealed in - any leaks would then be to outside. I have had to make it narrower to be able to do that but it is taller and longer so still holds about 10 gallons which should be enough.
 

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Puckle

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SUPER Site Supporter
I have got the fuel tank sealed off now and the new rear panel is in, time to start the bodywork at the front. I made a joggling jig for the press brake and used it to do the step down on the new scuttle panel, I'm now sorting new bonnet panels - not sure what to do about the louver's - it always distorts the panel when you try and press them into a flat sheet so I may cut out the old ones and rivet them in.
 

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Snowy Rivers

Well-known member
Saving the old louvers and riveting them in will work fine.
If you can, do it so it looks like it was supposed to be that way :hammer:

Looking good.

:thumbup::thumbup::thumbup:
 

Puckle

Well-known member
SUPER Site Supporter
Old louver's straightened out ok so took your advice and fitted them to new bonnet panel - I put them on top so it looks like it's supposed to to be that way, as you said.
 

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Puckle

Well-known member
SUPER Site Supporter
They are glued with JB weld and flush riveted - should blend in ok once painted.
 

JimVT

Bronze Member
GOLD Site Supporter
a few later ones had some up below the windshield. they need lots of cool air.
 

redsqwrl

Bronze Member
GOLD Site Supporter
Your skills are above average. ( way above)

I find watching such talent to be inspirational.

I might have to get off the couch and take hammer to rewire my trailer. :cool:
 

vintagebike

Well-known member
Flush head river screws

We will be using a bunch of these stainless rivet screws to attach new aluminum skin to our 1949 ‘Sophie’ Tucker
0B2B68C9-056E-443C-BCEC-312C99E10375.jpg
 

Puckle

Well-known member
SUPER Site Supporter
not seen those, presumably they have a nut on the back and there is enough grip from the serrations under the flange to nip them up. I used soft aluminium countersunk rivets which only need a couple of taps with a small hammer to secure them and the heads can easily be filed/sanded flush.
I do a lot of sailing and have always been a bit wary of stainless and aluminium - I use chromate paste to isolate any contact between the two or you get loads of corrosion but perhaps on dry land it is not so much of an issue?
 

vintagebike

Well-known member
Yep, rubber tape between the alu and the steel frame, chromate paste and paint are in the plan. Idaho treating the roads with calcium chloride is a real problem.
 

Snowy Rivers

Well-known member
Teach the children how to drive on the slick chit and NOT DUMP THE CAL CLOR ALL OVER THE ROADS.

Between that crap and the Salt....not sure which is worse.....
 

Puckle

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SUPER Site Supporter
New aluminium air horn fabb'd up today - trickier than I would have thought to get all the angles right - cardboard templates helped.
 

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redsqwrl

Bronze Member
GOLD Site Supporter
tricky is right.... put a oil cooler on the motor and lets chat.....

I think you did great. make sure to put a bird catcher on it. that way the mice can get in but the cat can't
 

Puckle

Well-known member
SUPER Site Supporter
Bonnet stay and gearbox cover today - I've modified the gearbox cover so that it will take a VW Golf gear stick boot - look a lot better than the standard bug one.
 

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KickerM

Active member
Site Supporter
GOLD Site Supporter
I wish I could come work for you (room and board only, I’m probably not worth more than that) and learn your skilled art of metal fab!
 

Puckle

Well-known member
SUPER Site Supporter
Slow progress now were on to shot blasting and painting, so far only managed back door frame and new slam plate and bumper bar. Also made new door skin and fixed the handle lock - its a vintage ford pop handle for some reason but I managed to find a new barrel on e-bay for a ford Anglia that was similar and re-built my old lock with the new tumblers and springs so it would fit the new keys.
 

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