1942 dodge ambulance resto

[jack neville]

A few more.

[jack neville]

aside from where I drilled around the roof welds to remove it, the remaining metal on the edges in many places is very thin or pin holed with rust. I decided to add a patch all the way around the edge to both fill the holes and reinforce the weak and thin areas. I want to avoid as much filler as possible as the drumming and vibration effect on these large panels will make any filler prone to cracking if it is excessive. I decided to press some raised areas in a metal strip so the finished surfaces will be level. I decided on a small patch and a larger one where required. A template was cut from a piece of metal and the applicable areas scribed and cut out.

[jack neville]

The template also forms part of a tool I made from scrap. A 60mm strip of metal is marked on the side of the roof where the pressing is relevent. The tool s assembled around the scribed area and then pressed to form a depression 1 mm deep to match the gap in the side of the roof.

[jack neville]

Each successive pressing is marked and stamped until that strip of metal is filled. The imprints are lining up perfectly and I only intend to tack weld around the circumference of each hole to minimize distortion. The surface of the patch and roof are level so the amount of filler will be confined to the circular groove around the patch. The strip behind should give sufficient support. That's the plan anyway.

[jack neville]

I have welded in the first strip to see how it goes. The patches have ground up quite flat so hopefully with a bit of filler and a bit more dressing the finished appearance will be acceptable.

[Bob Carriere]

Rather than introducing more heat in the panels have considered the liquid steel from JB weld....... works better on horizontal surfaces as it tends to self level...... and hard as steel...... works great on bare scuffed metal.

Enjoy following your progress.

Cheers

[jack neville]

Thanks Bob. I will minimise the amount of welding of the patches to simple tacks. The raised impressions should help stiffen the repairs and the repaired roof will be a snugger fit by two millimetres when refitted and rewelded to the body. It will need a thin layer of filler to finish off which has to be kept to a minimum as large panels like this have a problem with vibration which inevitably leads to cracking of excess filler. Being on a curved and reinforced surface should help. The original construction of these bodies has thin strips of bitumen like deadening between the outer panels and inner ribs. It was largely dried and cracked or missing by now and we intend to add a substantial layer of silicone in between those areas to assist gluing the panels to the ribs and reducing drumming and vibration. That as well as a decent layer of body deadener and insulation should further reduce heat build up as well. I imagine these tin boxes would get pretty hot in summer as originally constructed. And freezing cold in winter although they do come equipped with a heater. Jake will use this vehicle to camp in so now is the time to add what comfort we can. It will all be hidden once the masonite wall lining and ceiling go back in anyway.