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Duncan's 71 "Oz" Goon


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#21 datrod

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Posted 09 January 2012 - 06:55 PM

Mark.
Did you try a scotch brite pad on an air grinder. I don't know if it will do the job for you but I've used it many times at the shop to remove crap before welding.

I also have a rubber like deal that we have used for deburring parts. If ya want I'll bring a couple to the Mo Valley meet.

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#22 Duncan

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Posted 09 January 2012 - 08:50 PM

Mark.
Did you try a scotch brite pad on an air grinder. I don't know if it will do the job for you but I've used it many times at the shop to remove crap before welding.

I also have a rubber like deal that we have used for deburring parts. If ya want I'll bring a couple to the Mo Valley meet.


Thanks John,
Cleaning it prior to welding isn't too much of a big deal, it's getting that insulation / sound deadening crap off that is very tedious. Looks like my chisel-hammer-scraper method is the way to do it. I'll try some chemical treatments on the glue residue once I get most of it off.

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#23 INDY510

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Posted 11 January 2012 - 11:00 AM

.
a few pics from the Nor-Cal meet on April 23rd 2010:


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#24 Duncan

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Posted 11 January 2012 - 05:38 PM

.
a few pics from the Nor-Cal meet on April 23rd 2010:


Thanks for the photos, Indy. That was a nice trip. I was going to bring my Sunny, but it rained on my day to travel up there, and the Sunny is a fair-weather car only. Maybe this year the weather will cooperate.

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#25 Duncan

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Posted 13 January 2012 - 05:09 PM

This doesn't look like much, but was an assload of work..

Something came up just as I was about to go and fill one or two voids in the welds, but the passenger floor is mostly done..

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#26 Keithj

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Posted 27 February 2012 - 07:11 PM

Nice goon and attention to detail.

#27 Duncan

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Posted 04 March 2012 - 08:08 AM

I haven't posted in a while, but I have been working on the goon. I didn't take a lot of photos, but work is underway on replacing both quarter panels.

I have a friend who is a master metal worker and is retired from his job as a welder at a nuclear power plant. (Strange, but true) His shop is in San Diego, so we moved the car down there and I have spending a lot of time down South working on it. I'm doing most of the work, but Smitty is supervising to keep me out of trouble :)

I had to drill a zillion spot welds out on the replacement panels to get down to the skin only, and that took a few weekends. Next, we repeated the process on the car itself. The passenger side seemed the worse, so I'm tackling that first.

Here's a photos of the left side with the quarter removed.

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I also discovered some rust in the drip rail area, and made a tool to bend a replacement piece for it. It's actually two pieces in that area, so both were duplicated. Here are the two pieces tacked in with the mig, but the tig welder will be used for the finish weld.

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I'll try to get some better pics as we continue..

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#28 Duncan

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Posted 04 March 2012 - 08:18 AM

I haven't updated this thread much, but I keep slugging away steadily on the goon. The left-side quarter is completely installed, the welds all ground, and will be in completely cleaned and etch primed by next week.

At the beginning of May, my buddy was moving some cars around his shop, and this quarter panel was on the ground next to my goon. Someone wasn't paying attention, and this was run over along one of the top edges. I truly thought it was hopeless, but my buddy Smitty was able to straighten it out. It is now on the car and you would never know where the damage was. I still can't believe he got it completely repaired.

Save some very small amount of damage repair done by vice grips, this side is done. Instead of bondo, I am going old school and will be lead filling. When I get to that point, I will document the process.

We are looking hard at the driver's side right now, and we both think we can get away with either repairing or replacing the dog leg only. I certainly hope so..

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#29 Duncan

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Posted 10 June 2012 - 11:05 AM

I posted the above today, but I edited an old post, so it didn't bring the thread back up. Found another photo from yesterday, so one more oic w/ a thread bump!

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#30 greengoon

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Posted 11 June 2012 - 08:04 AM

Wow, Mark that's a lot of work. I'm impressed. It will definitely be up to the standards you are known for.

#31 Duncan

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Posted 24 June 2012 - 06:48 AM

The passenger side is finally on and in a coat of self-etch primer.

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So we are moving on to the driver's side...

After some extensive assessment, I decided to replace only the dogleg section on this side. The rust issues were mostly on the passenger side, so (for once) I actually caught a break.

Here's the dogleg section removed.

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This isn't nearly as bad as the other side. We will also attach a big clamp and pull out the dent on the bottom of the rocker. I had an identical dent in the same spot on the other side. I'm pretty sure it was done with a floor jack by someone who had no clue what they were doing..

My donor section had some unseen issues. It looked very clean with the paint on it, but 40 years took it's toll on it.

Here's some in-process repair photos.

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Yesterday was the first time I have tig welded in over 5 years. My friend is very old school, and his welder has no foot pedal! I did some practice runs on some old scrap and (sort of) got the hang of it again. The welds aren't pretty, but they are good and solid.

All that's left now is to cut and weld the last piece into the dogleg, and the repairs on it will be done.

Next up will be fixing the inner section so I can install the replacement dogleg.

I am headed up to NorCal next weekend to the Bayline Gathering. I will be bringing my Sunny, and I hope to meet a few of you and to see some old friends. -Mark

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#32 Duncan

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Posted 24 June 2012 - 06:07 PM

And thanks Duane. Mine will be a bit different, but hopefully as cool as your goon when I get it done.

BTW, I did see your filmed interview and it was awesome. Your cars are great, and the area you live in looks gorgeous. Very nice, indeed.

Wow, Mark that's a lot of work. I'm impressed. It will definitely be up to the standards you are known for.


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#33 greengoon

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Posted 25 June 2012 - 04:07 AM

^ Thanks, Mark. There are definitely finer cars out there so I was honored to be able to have Josh make the video. I've suggested that he come out to JCCS. That canyon is about 20 minutes from my house so if you ever make it out this way, I'll give you the tour. :)

#34 Duncan

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Posted 07 July 2012 - 11:50 AM

More exciting (translation: non-glamorous) work.

I went up to the Bay Area last week, and my friend in San Diego was out this weekend, so I started on one of numerous side projects.

I HATE undercoating, so I generally remove it where I can. Here's a before and after on one of the fenders.

The insides of both fenders looked like this, so I decided to clean them up and paint them. I only did one today, but tomorrow I will do the blue one and get both insides done with some self-etch primer. I'm doing the insides (eventually) in the body color.

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yawn....

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#35 KELMO

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Posted 08 July 2012 - 03:49 AM

Yes that is very non glamorous.......but its that kind of stuff that make people look at your cars and say Damn, it probably also helps to contribute to the awards you have.

Can't wait to this one finished.
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#36 Ratwagon1600

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Posted 08 July 2012 - 12:56 PM

Yeehah!! Someone else who doesn't like Undercoat (body tar). I'm sure the nice Man who did my wagon all those years ago was drunk as on my wagon the stuff is everywhere and really thick too! It takes forever to get off.

Great work on the quarter panels!

Hahahaha RW bring called an ass kisser is awesome. Don't know him personally but he always seemed belligerent, not brown nosey.

You have standards?

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#37 Duncan

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Posted 08 July 2012 - 01:57 PM

Thanks guys,
HOT TIP for removing undercoating. Apply JASCO paint and enamel stripper liberally with a disposable brush, let it sit for about 10 minutes, and the stuff will come (mostly) right off with a putty knife. It's still a messy job, but it beats using a power tool and having the shit fly all over :)

I just primered both fenders and they look very clean inside. Even though I am going to buy paint from out of State, I have some Cal-compliant acrylic enamel paint in my color for stuff like this which will do just fine.

Kelly,
I made my reservations for Williams, AZ again. Looking forward to seeing you again if you can make it...

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#38 KELMO

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Posted 08 July 2012 - 03:21 PM

Registration is supposed to start on the 15th of July (according to Nostalgic Datsun). I am planning on being there...with a Datsun or with 2 Datsuns or without....depends on what is running that week, most likely be the grey one again. Lookin forward to seein ya, are ya bringing anything?
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#39 Duncan

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Posted 15 July 2012 - 08:59 AM

Kelly,
I just got the e-mail on registration and I'll be there in the Sunny again. The goon would be nice, but it's got a bit more work to go before I can show it :)

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#40 Duncan

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Posted 15 July 2012 - 09:10 AM

I got quite a bit done yesterday.

Here is the finished dogleg section ready for install.

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Like the opposite side of the car, the bottom of the rocker panel was dented in the exact same spot. I assume someone with a floor jack thought this was a good spot to jack up the car. Not good. I did this many times when I restored the '55 Caddie. Here's the clamp and floor jack method.

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Straightened out nice and easy..

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We also got well into the inner dogleg support repair. (You can see how rotten it is above)

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Needs to have the welds ground down and cleaned nicely, but the fab work is mostly done. The big sloppy looking welds at the very top were done to fix some holes that blew open while welding. It happens a lot when welding new metal to older stuff. We are also going to repair the small tear in the bottom of the rocker. That will also get cleaned very nicely and painted before the dogleg install.

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