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Turquoise 57 New Yorker Coupe
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Powerflite
Posted 2018-11-20 1:17 AM (#573828 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Thanks James and Garrett. I don't usually dive headfirst into rust repair, but in this case, I had to. We decided not to travel this Thanksgiving so I should get a good block of time to work on it this weekend. I hope I get as much done as I envisioned in my head; which pretty much never happens.
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macedon
Posted 2018-11-20 9:16 AM (#573839 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Wow. Fantastic progress in such a short time. Congrats. You are welcome to stop by my shop anytime.
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Powerflite
Posted 2018-11-23 8:52 PM (#574039 - in reply to #573839)
Subject: Re: Turquoise 57 New Yorker Coupe



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Thanks Dave, if I am ever in your part of Texas, I definitely will!

I finished welding the inner qtr panel and painted it. I had to remove the undercoating on it first. I made it out of a door skin from a '63 Nova I had laying around. But I wish I would have put the undercoating on the other side of the panel. It was a real pain to get it off. I didn't want it on the inside for fear of it eventually coming off and clogging up the drain with bare metal underneath it.

It looks like someone tried to lift the car by the rusted rocker and bent up all the inner metal on it. It took me quite a while, but I managed to unbend all the inner rocker and got it in the proper position again. The outer metal there was torn up & rusted so I tacked an entire new rocker over the top of it to give it strength and welded up a number of cracks & holes in the surrounding metal.

After that was done, I got to install my sweet new qtr panel. It went on really easily, and the only issue with it was the metal stuck out a little too far near the wheel lip so I had to massage it into shape before I welded it in. I paint all the in-between sides before I weld them together, mark the locations for the spot welds, and lightly grind the paint off with a tiny cutter. THat way, I get paint all between the joints. I didn't finish welding it because I wanted to get to the frame swap ASAP. I will finish welding it and clean up the welds in the next week or so, but it was now strong enough to lift so I went ahead and did it. I was able to pull the old frame out tonight and stripped most of the stuff off of it in the dark. Tomorrow, I will get the new frame under there and cut up the old one.



(57NY Left Rocker Cover.jpg)



(57NY Left Rear Qtr Welded.jpg)



(57NY Frame Extraction.jpg)



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Attachments 57NY Left Rocker Cover.jpg (147KB - 53 downloads)
Attachments 57NY Left Rear Qtr Welded.jpg (139KB - 53 downloads)
Attachments 57NY Frame Extraction.jpg (155KB - 56 downloads)
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DejaVu
Posted 2018-11-25 4:32 AM (#574089 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe


Member

Posts: 13

It is thoroughly impressive to see the pace with which you attack these repairs. I'd love to see timelapse video of your driveway over the last year or so!

Keep up the great work!
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Powerflite
Posted 2018-11-25 9:34 AM (#574093 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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Thanks Ian, having a block of time off work helps alot

I decided to paint the rear axle housing before I button it up to the new frame so I didn't get to install it yesterday. The leaf springs are the originals to the new '57 Windsor frame that are in great shape. The New Yorker leafs went into the scrap bin. But I had to use all of the hardware from the New Yorker as I can't seem to find the hardware from the Windsor. I know it's somewhere in my garage! It's a lot of manual labor swapping suspension parts around. My muscles aren't real happy this morning. Looking at the T-bars yesterday, I noticed that the right side was visibly bent. The left is very slightly bent, but probably livable. Strange, because I would have expected it to be the other way around since the frame was cut on the left side. So it looks like I will be using the Windsor bars on the car, which have the same part numbers anyway. It seems this car had a hard life in its past.



(57NY Frame Install.jpg)



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Attachments 57NY Frame Install.jpg (177KB - 49 downloads)
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Powerflite
Posted 2018-12-04 3:16 PM (#574634 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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I got the frame in last week, but I set the body down in the back on 2 boards lying across the hump. So the rear part of the body is resting on those instead of the frame and makes it sit higher in the back. But the front part is sitting on the frame mounts with the bolts loosely installed. I did this because I have 3 rear body mounts that need work.

I think I am going to only fix the 2 most rear mounts right now and save the other 1 for later, just to be able to get the car put together more quickly. The first mount I am working on is a result of someone cutting the mount out of the body. I presume that this was a shortcut to not having to remove a rusted nut, but cutting it like that doesn't look easy to do, so I am at a loss to explain the reasoning behind it. I will have to make a new panel for it and weld it in place. Not easy to do, because it will likely have to be done upside down. I HATE upside down welding. I still have burn marks on my chest from the last time one of those lava balls found it's way into there. The other mount is rusted in that area and requires a patch.

I also cleaned up & painted the front control arms on the car and re-installed them to the new frame. I was surprised to find out that I couldn't re-use the old hardware from the New Yorker because they used 1/2"-20 fine threaded bolts, and the '57 Windsor frame uses 1/2"-13 coarse threaded bolts. What the?! So I checked out all my other cars and found that all the earlier '57 vehicles used the fine threaded bolts, and all the really late '57 & '58 cars used the coarse thread. This '57 Windsor frame was from a really late production build. Luckily, I managed to find the old Windsor hardware to put it back together. Now I just need to find that alignment wedge for the steering box!

Finally, it took me a while, but I got the trunk lid back on, and latched in place. I had to remove a broken bolt from it, make a tool to re-attach the trunk springs, and find my extra catch that was missing from the car. But it is done now and works well. That was the biggest priority I had because it's a pain to try and keep rain out of there with it off.



(57NY Rear Body Mount Missing.jpg)



(57NY Front Suspension.jpg)



Attachments
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Attachments 57NY Rear Body Mount Missing.jpg (174KB - 45 downloads)
Attachments 57NY Front Suspension.jpg (198KB - 49 downloads)
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Powerflite
Posted 2018-12-16 12:00 PM (#575327 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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I cleaned up the welds on the quarter panel repair and made a first pass at the hammer & dolly work to smooth it out. This is likely the easiest lower quarter repair job I have ever done. This hobby is a lot more fun when you have good replacement panels to work with. It needs just a little more hammer work to get it perfect, but is real close now.

I also ground down the surface rust on the quarter along with some of the bondo that is there, sprayed it with a rust converter and painted it to preserve it better. Then I replaced the spear side trim with one that is 2" longer (the right length) so that it will reach all the way to the tail light properly. Not sure why that one is so short. It doesn't look to have been repaired or messed with so I don't know what happened with it.

I also repaired the left rear body mount that someone had cut out. It came out much better than I expected. I could probably clean it up a little better if I had the body on a rotisserie, but it came out surprisingly well anyway. One down, 2 to go before I can finally set the body down.



(57NY Qtr Finish.jpg)



(57NY RearMount Weld Top.jpg)



(57NY RearMount Weld.jpg)



Attachments
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Attachments 57NY Qtr Finish.jpg (114KB - 45 downloads)
Attachments 57NY RearMount Weld Top.jpg (210KB - 48 downloads)
Attachments 57NY RearMount Weld.jpg (169KB - 45 downloads)
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mikes2nd
Posted 2018-12-16 12:42 PM (#575333 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe


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heh been there, done exactly that same weld
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firedome
Posted 2018-12-17 10:52 AM (#575384 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Clearly this car went to the right home, great start!
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finsruskw
Posted 2018-12-17 4:16 PM (#575391 - in reply to #575384)
Subject: Re: Turquoise 57 New Yorker Coupe



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Do you have any of this to deal with??





(300C_floor_pan_002.jpg)



(300C_floor_pan_008.jpg)



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Attachments 300C_floor_pan_002.jpg (59KB - 45 downloads)
Attachments 300C_floor_pan_008.jpg (49KB - 47 downloads)
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Powerflite
Posted 2018-12-18 12:21 AM (#575415 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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Thanks Roger. Dave, yes, of course I do. Even my California cars with very little rust have that issue. Those were designed very poorly. If you are repairing them, make sure you paint them in between the parts before you weld them together. Once condensation or other moisture gets in there, it's pretty much game over if they are bare metal contact...and of course they are the lowest point in the car so that's where any water will naturally go.

This is the second rear mount I am repairing. This one is much more involved, but I made a good start on it by making a repair panel for it from a '63 Nova door skin. It wasn't easy to make due to all of the compound curves on it and it isn't quite finished yet. I am going to cut the vertical bend very short so that it is barely above the bottom of it. Some of that edge needs a little more massaging as well to get it right. Once I cut the old one off, I can better see how it needs to be modified to get it right, and I will use it as a template to get the hole in the right spot too.



(57NY Rusted Rt Rear Mount.jpg)



(57NY Rt Body Mount Replacement.jpg)



Attachments
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Attachments 57NY Rusted Rt Rear Mount.jpg (122KB - 50 downloads)
Attachments 57NY Rt Body Mount Replacement.jpg (170KB - 47 downloads)
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finsruskw
Posted 2018-12-18 8:23 AM (#575424 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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I made my pieces from scratch well.
If you remove the original in one piece by cutting/drilling the spot welds ad can line it with something,
Then fill the trough with plaster or cement.
When it sets remove the casting and use it as a base form for making a template to lay thin cardboard over it.
It will become obvious at this point where it needs to bend an lap back onto itself to make the tray.
Mark the cardboard where the bends need to be, allowing 3/4" or so for the lap joints front and rear
Cut out the cardboard to use as a paattern. You will find there is a slight difference between the lt and rt sides.

Then lay the pattern on a piece of new sheet metal, trace and cut.
I used a homade break for my press to do the bends, kind ofa PITA though, whatever you do.
I cranked out 8 or 9 pairs of these and sold them years ago, some went clear to New Zeeland!!

It was fun figuring it out,,,,,then…. and doing it!
But now it would just be work....and I'm retred!! insert smiley face (here)
I have a few more pic's somewhere
I was lucky to have OEM NOS rockers to work with.
You can see the rest of the sheet metal work on the car here

http://www.chrysler300club.com/tech/schwandt/schwandt.html




Edited by finsruskw 2018-12-18 8:29 AM
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Powerflite
Posted 2018-12-18 1:41 PM (#575438 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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Nice job Dave. I hand made those things for my copper '57 Windsor as well. It wasn't very easy to do and I don't really want to do it again, but I need at least 2 more sets of them now. Jan in Sweden makes them, but it can be quite expensive to ship so I am not sure what I will do yet. I may just leave them alone! Heaven knows I've got plenty of other issues to deal with.

I got the disc brakes installed on the car. The long bottom bolt was a huge headache on both sides. They were totally seized in the steering arms. I had to cut them into 4 pieces and heat the remainder of the bolts red hot to eventually get them out of there. I broke my only 1/2" drive 5/8 socket trying to turn them with a breaker bar so I need to head to the tool store today. But it's done so all is good. Just need to bend the lines & install the power brake pedal assembly since the car originally came with manual brakes.



(57NY Disc Brakes.jpg)



Attachments
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Attachments 57NY Disc Brakes.jpg (149KB - 43 downloads)
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finsruskw
Posted 2018-12-18 1:54 PM (#575441 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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What are you gonna do for a MC?
Was it all a bolt on deal?
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Powerflite
Posted 2018-12-18 2:25 PM (#575445 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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Yes, a bolt-on from Scarebird. It requires 15" wheels. With power brakes, I like to run a remote-fill master. I can no longer purchase the master shown on my car in the picture, so I will try to use one from a 1990 Mitsubishi FUSO truck that has a 1.125" bore size. It's a 4-bolt master like the Chrysler units, but the mounting holes have to be moved outward a little to make it work. I'm not sure yet how it will turn out, but I'm sure I can get it to work.



(57NY Firewall Closer.jpg)



(dhb-m630742_hn_xl.jpg)



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Attachments 57NY Firewall Closer.jpg (188KB - 40 downloads)
Attachments dhb-m630742_hn_xl.jpg (126KB - 49 downloads)
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Powerflite
Posted 2019-02-28 11:04 AM (#578706 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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I purchased these air cleaners for the car from Smitty. They look like a complete basket case, so they should fit right in with the general theme of this car. But I figure that I can cut the spot welds, cut an appropriate sized hole into a new lid and spot weld it back onto them. That's the plan anyway.



(Sad Air Cleaners.jpg)



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Attachments Sad Air Cleaners.jpg (250KB - 27 downloads)
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billy
Posted 2019-02-28 11:29 AM (#578708 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Looking Good Nathan
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Powerflite
Posted 2019-03-02 10:48 PM (#578799 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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Thanks Billy. Hopefully this weather will let up a little so you can enjoy driving yours again.

I wasn't planning to work on this today, but it was raining most of the day so I spent my time working inside the garage instead of doing what I had planned. These air cleaners were reaching out to me with their tetanus fingers so I decided to do something with them. I pulled two new lids from my attic and marked them to cut a proper hole into them. The originals have a 4.25" hole. Then I rather sloppily cut them out with a plasma cutter and cleaned up the cut to my mark with a tungsten-carbide bur on a die grinder. The center pad smokes forever when you do this, but the rain eventually put it out so I didn't have to mess with it. I also spent quite a bit of time to straighten one tube out as it had been bent up quite a bit. I had to use a long bent punch that I made for a different application; but that was able to reach down inside them and pop out all the problem areas. I made a new tab out of 1/8" plate to replace the missing one on it. I bent the radius on the bottom of it by separating my vise jaws to create a gap and hammering a rod onto the tab, into the gap. It worked out quite well.

Rather than split all the spot welds for the flange that the lid welds to, I just cut a slot into it so that I could slip the lid over it. I'll weld up that slot before I spot weld them together....the problem is that I didn't own a spot welder and have never done it before. I didn't want to plug weld these so I went to Harbor Freight and bought a 240v version. I just need to practice with it and see how to do it before I try my hand with the real thing. Spot welding the tab may not work real well, so I may end up plug welding that one. We'll see.

Edited by Powerflite 2019-03-02 10:52 PM




(New Recruits.jpg)



(Fire In The Hole.jpg)



(Straight With New Tab.jpg)



(Just Add Spots.jpg)



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Attachments New Recruits.jpg (162KB - 25 downloads)
Attachments Fire In The Hole.jpg (193KB - 23 downloads)
Attachments Straight With New Tab.jpg (92KB - 22 downloads)
Attachments Just Add Spots.jpg (114KB - 23 downloads)
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Powerflite
Posted 2019-03-19 12:38 PM (#579538 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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The rust holes in the left wheel lip started to bug me every time I walked past them. So I decided to fix them so I don't have to look at them any longer. I fixed most of the inner wheel house issues, the top of the wheel lip and the upper front section of the lower lip. I still have to do the lower section along most of it, but that part is less visible. My subconscious feels much better now. We are expecting more rain so I had to epoxy prime it right away. There is a little dip in the lip right where the new quarter was welded on, so I need to weld that back in as well. Sometimes I don't see all the issues until it is all one uniform color.

Edited by Powerflite 2019-03-19 12:48 PM




(57NY Left Wheel Lip Top Repaired.jpg)



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Attachments 57NY Left Wheel Lip Top Repaired.jpg (99KB - 17 downloads)
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57burb
Posted 2019-03-19 4:05 PM (#579546 - in reply to #578706)
Subject: RE: Turquoise 57 New Yorker Coupe



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Some great progress! Those air cleaners were a real mess, wow...
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Powerflite
Posted 2019-03-20 12:11 AM (#579570 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Thanks, they were worse than they look. I spent a couple of hours straightening them after separating the junk lids from them.
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Powerflite
Posted 2019-03-22 7:38 PM (#579726 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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In order to replace the rear body mount on the right side, I needed to replace the trunk drop down first since they get welded together. And to do that, I needed to get the outer quarter squared away as well. So I cut the replacement quarter to fit up to the old quarter and get it ready to weld in the right spot before I replace the drop down. This way I can ensure that I get it in the right location when I put it back together. I also measured out the height and compared it with my other vehicles as it is easy to get it 1/4" off. Now I will bend up a new trunk drop down and weld that in place after I check the fit with the replacement quarter. I'm all out of Nova door skins so I'll cut up a '57 Windsor sedan rear door to use for it.




(57NY RtRr Quarter Placement.jpg)



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Attachments 57NY RtRr Quarter Placement.jpg (163KB - 18 downloads)
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Powerflite
Posted 2019-03-22 9:35 PM (#579730 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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The drop down is out. Needs just a little patching and cleaning up before a new panel can go in. I am keeping the old one around to use as a pattern for the new panel.



(57NY RR Drop Down Removed.jpg)



(57NY Rubbish.jpg)



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Attachments 57NY RR Drop Down Removed.jpg (169KB - 17 downloads)
Attachments 57NY Rubbish.jpg (287KB - 17 downloads)
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wizard
Posted 2019-03-23 6:55 AM (#579747 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Good work, keep it up and you'll soon cruise down the lane
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Powerflite
Posted 2019-04-06 11:09 PM (#580470 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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Thanks Sven. This one is very needy, but I do enjoy working on it.

I finished fabricating the trunk drop-down for it. I had a couple of false starts with incorrect dimensions, but once I got it figured out, it came together pretty well. I just need to cut the holes into it so I can plug weld it back into the trunk pan. The white residue that you see is what remains of the thick bondo slathered on the Windsor door that I cut this panel from. I left the bottom flange extra wide so I can trim it to size once I get the outer panel welded to it. It would have been really nice to be able to purchase this part, but the crap that is available here is completely worthless. Comparing the two photos, the top portion doesn't look to be wide enough and it doesn't have the required taper in its width that the original has either. The angle & length of the front up-flange is all wrong, and doesn't include the tab for mounting the section to the wheelhouse. Who knows what they had in mind at the back-end of it. They included some artistic flair that has nothing to do with what is needed. And the bottom flange edge isn't straight. It has some weird kink in it for some stupid reason. He also bent the flange that welds to the trunk pan in the wrong direction! It was supposed to bend up, not down. What the heck?? Can we get someone who isn't completely blind and stupid to make parts for us instead? Until then, all we have is Dopey's workshop building us parts. If Real Steel Replacements were to make some good trunk drop downs, that would be a nice change, but I don't want to be the first one to try it out from him, so I made it myself.

Edited by Powerflite 2019-04-06 11:19 PM




(57NY Rt Trunk DropDown.jpg)



(Crap.jpg)



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Attachments 57NY Rt Trunk DropDown.jpg (174KB - 11 downloads)
Attachments Crap.jpg (57KB - 11 downloads)
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Powerflite
Posted 2019-04-09 1:15 AM (#580570 - in reply to #572778)
Subject: RE: Turquoise 57 New Yorker Coupe



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I made up a template in Solidworks in case I need to make another one of these for a different car in the future. Starting with a good template makes the work go much easier. This is for the right side. In theory, you could just bend it the opposite way to get the left side, but the left has a rectangular hump in the middle of it for the spare tire to rest on, so it is a little different. The rear part of it needs to be split at the top of the bend to go upward a bit (see the part that I made above). Afterward, you need to add material to match up to it from the side as well. The numbers seem more accurate than they really are. They didn't come out as round numbers just because Solidworks takes into account the bend radius that I used, which was set at 0.1". But these numbers are just pretty close so you should check everything first before you make your bends. I hope it helps someone.

Edited by Powerflite 2019-04-09 1:20 AM




(Trunk Dropdown Model.jpg)



(Trunk Dropdown Drawing.jpg)



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Attachments Trunk Dropdown Model.jpg (32KB - 12 downloads)
Attachments Trunk Dropdown Drawing.jpg (70KB - 12 downloads)
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wizard
Posted 2019-04-09 3:09 AM (#580577 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Thanks' a lot Nathan, this will help many guys to make those repair parts - really nice to have it made in Solidworks as well.

Hypothetically, with that file and a hard core sheetmetal company it would be possible to get those panels cut and bent directly from file.
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miquelonbrad
Posted 2019-04-11 9:10 AM (#580712 - in reply to #572778)
Subject: Re: Turquoise 57 New Yorker Coupe



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Nice job Nathan!!!
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