1942 dodge ambulance resto

[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.

[jack neville]

The roof patches have all been added and I have tidied up the dents as best I can in this position. There is more repair work to do which needs to be done with the roof back on. I decided to refit it now to see how it looks at this stage. It is a difficult thing to handle.

[jack neville]

The roof sat back with a little jiggling and the use of a hand winch diagonally to square the top up. The repairs had spread the sides and rear outwards a bit but fortunately it has a substantially strong gutter. With the use of ratchet straps to put downward pressure on the roof I was able to bang wooden wedges all around to hold it in place. I then ran a speedfile over the roof to check for dents. I then pulled all the wedges out and lifted the roof back up so I could get a curved dolly underneath and dress up the last remaining dents.

[jack neville]

I have got the rear part of the roof pretty good. The front piece over the cab has a couple of cracks and some dents that should come out easily. These insert sections above the doors are a problem. Especially the right side.

[jack neville]

The left side not as bad.

[Bob Carriere]

......going were few men have gone before......

In the Dodge power wagon forum they warn about disassembly of the large open bodies like yours as they are inadvertently very hard to put back together.

Been following your progress and fascinated by the bravery to tackle sheet metal that has become like a saltine cracker.

How will you form your patches???? do you use an English wheel or maybe a sand bag and hard rubber mallets........?

Love that wooden wedge trick.

Cheers

[jack neville]

lucky we haven't read the Dodge forum Bob. Haven't worked out those patches yet. They curve in both directions.

These photos show what I needed to do to square up the roof.