What's going on in my little Garage....

Keyblazer · Oct 3, 2018

Not in any way, am I an accomplished fabricator/welder/restorer, etc, but i'm having fun just the same.

Just an old guy, on a low budget, with a passion for making/fixing/doing stuff, and I thought I'd make my own thread to share what I'm up to in my 2 car garage..

This will be a mixture of "show and tell", Tool purchases, and restorations, modifications, questions, and all of it will be low budget, and I hope interesting!

I have posted a lot of this stuff on other threads, but its all over the place, so I will kinda consolidate it all here.

Let me pull together some stuff to share!

Keyblazer · Oct 3, 2018

Lets start with something that is NOT in the garage....

Our "Retirement Plan Motorhome".

Always loved Airstreams, but didn't want a trailer... wanted a Motorhome...
So, much to my surprise, I found that Airstream had answered my wish already, from 1970's thru 1990's.

Let me introduce my 1984 Airstream Classic LE 345.
This how it looked when I bought it...

And now...

Lots and lots to do, but this beast will explain a lot of what I am up to!

protegeV · Oct 3, 2018

Oh man, that is epic! Would love to see pics of the interior

Keyblazer · Oct 3, 2018

Pretty much stock inside at the moment, altho I am planning/working on a Leather interior upgrade... the 80's called and wanted its velour back..

The Cockpit seats are horrible, and so Im working to upgrade and install some 1998 Range Rover P38 seats up there...
Got a pair from the Junkyard, and am recovering them in chocolate leather...

My Consew 206RB..

Keyblazer · Oct 3, 2018

So, patterning out the lower cushion...

First attempt... not perfect, but pleased with it!

2oolhound · Oct 3, 2018

Nice work. Great upgrade. How long is that vehicle and what engine and trans?

Keyblazer · Oct 3, 2018

The Airstream has a lot of dings and dents, and so I know I would need to replace/repair/fabricate some new panels, especially as many parts are NLA.

345 Model, so 34.5" long.
Chassis is Chevy P30/P32... Commonly known as a Step Van chassis… think Food truck... ups delivery truck.
This particular chassis is the forward control Motorhome version.
Airstream stretched the chassis and added a tag axle to support the extra weight.
Weighs 16,500lb.
Engine is currently a Chevy Big Block 454(Jasper Rebuilt 5k miles ago), with Carb, and Banks kit, backed with a 3 speed TH475(Think Th400 with straight cut sun gears).

I have a 4L80E and a Cummins 5.9 12v floating around...

So, to make stuff, ya need tools, right?

And tools cost $, which I dont have a lot of... so I scour CL, and the like for stuff...
Here are a few that I have found, bought, restored and using to get me moving forward...
Hope this is an inspiration for others who have needs, but not $$!

HF 4x6 Bandsaw... $50.

HF 30" Combo Shear/Brake/Sliproll machine... $100.

Dee-blast media Cabinet... $100...
This one was kinda funny... saw it on CL, went to see, and the seller said it didn't work...
The gloves were disintegrated, the glass was broken, but the hopper was FULL to the grates with concrete like media!
No moisure filter!
Took me an hour of scraping and chipping to get it all out to be able to load it in my truck!!!

First iteration of the restoration was this...

Since added a larger window, better gun, but still more to do.

Also added a little HF Soda blaster that I can snake in to do more delicate stuff...

I'd really like to upgrade the filtration system... but maybe I should do the whole wet blast conversion!

Keyblazer · Oct 3, 2018

With the cabinet, I needed more air...

Found this 80 gallon Speedaire upright... 7.5hp... Its a beast.
Next to my original... :thumbup:

With Media blasting comes the need to Powder Coat right?
Eastwood Dual gun...

Free double oven of CL!

Airstream Headlamp Casting...

Oh... and I maybe forgot to mention... I have a soft spot for Alfa Romeo...
So, did these V6 Valve covers for a buddy...

After..

8man · Oct 3, 2018

Looks like you are having fun. Nice work.

Toolfool · Oct 3, 2018

Very cool! Subscribed.

larry4406 · Oct 3, 2018

Way cool!

Keyblazer · Oct 3, 2018

Thanks Guys!

Its gonna be a kinda eclectic ride.... :headscrat

I do 99% stuff for myself, but like to help Buddies when they ask too...
On such request was from an Alfa buddy that needed an engine stand to build and detail his '59 Guilietta Veloca motor... He wanted to be able to spin it thru 360deg both ways.

This is what I came up with...

And bolted that, to a cheap HF engine stand...

This is how it worked out... he was able to spin it and scrub/detail/prep each side!

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rsanter · Oct 3, 2018

Keyblazer said:
Lets start with something that is NOT in the garage....

Our "Retirement Plan Motorhome".

Always loved Airstreams, but didn't want a trailer... wanted a Motorhome...
So, much to my surprise, I found that Airstream had answered my wish already, from 1970's thru 1990's.

Let me introduce my 1984 Airstream Classic LE 345.
This how it looked when I bought it...

And now...

Lots and lots to do, but this beast will explain a lot of what I am up to!

Looks good
Now you need to add the ‘nose art’

Keyblazer · Oct 3, 2018

I generally believe that most good quality tools are beyond my budget...

But sometimes, you stumble across a gem...

Responding to a CL ad, for and English Wheel, which I will need for some stuff I wanted to make...

I got this HF unit for $60...

Then there, in the corner, rusting away is...
Hossfeld #2 Bender... Stand, and some tooling... Because I bought a lot of stuff that day on a package deal, I cant definitively say what I paid, but $200 was a number I think we were about at...

A LOT of hours later...

Keyblazer · Oct 3, 2018

Also scored this Columbia Drill Press for $30... Untested and unloved...

Bought it back to life...

Keyblazer · Oct 3, 2018

The HF E-Wheel is a little maligned in the metalworking circles...
The one I found was the better of the two designs they did(the other has a curved upper section).
It is known to be too floppy/flexible, poor bearings, and misaligned.

Im a noob metal shaper, but I managed to use it a little and was pleased with what I could do without mods!

After reading up about mods that can be done, I had a plan...
A stiff backbone and bridge to minimize the flex...

Keyblazer · Oct 3, 2018

I wanted for this machine to be a "One Stop Station"...
So I added Brackets, for a pivot for the Planishing Hammer...

And an outrigger leg, with 2" Trailer hitch to drop other tools into..
In this case, a Wheel Polishing station...

So, I ended up with this:
Sheet Metal station... English wheel, Planishing hammer, and Bead Roller Station
:bounce:

Keyblazer · Oct 3, 2018

Oh, and there was this unloved HF beadroller I got.... I wanna say $50.
She was a little rough, but my plan involved a big makeover, and I just needed the basics!

Bead%20roller%20off%20CL_zpsh8o4kk8e.jpg

After a lot of love, and mods, she looks like this...

dogdog · Oct 3, 2018

wow

Keyblazer · Oct 3, 2018

I think this picture of the frame under modification sums it up...

Anyway, The details...
HF beadroller, with added frame stiffening. Frame milled to allow about 1" of shaft adjustment. The Aluminum bearing blocks were horribly worn, so rebushed with Phosphor Bronze units. Bearing block bolts were drilled thru and grease ******* added. Quick release handle on top.
Machinists... dont hate me for the way I bored the bearing blocks... I dont have a face plate or 4 jaw... but this worked 4x!

Drive unit is a HF Pipe Threader, on a home made nut... HF foot switch for $15ish, and Router Speed reducer for $15ish. Works well enough.

Keyblazer · Oct 3, 2018

Works great altho reversing is a PITA at the moment....

larry4406 · Oct 3, 2018

You have been quite busy and holding back....

Keyblazer · Oct 3, 2018

I hope this thread is worthy....
There have been many times I was in despair over my limited $/space/equipment, and I hope people see that you dont need $$$ to build a functional fabrication workshop.

The boring stuff is the stuff I got ready to go, new... Not complaining tho...
My GF did it... what a girl she is!
Eastwood TiG 200, and Plasma Versa-Cut 40… a Birthday gift.

My MiG is older but I love it...

Snapon Mussle Mig SL140…
110v unit so limited to 140a, but came with a Spool Gun and the Scratch start TiG gun too!

Keyblazer · Oct 3, 2018

larry4406 said:
You have been quite busy and holding back....

LOL!
I have posted a lot of this stuff before... I just thought I had enough fun and inspirational stuff to do a dedicated thread...

So, enough of the crazy tool refurbs... lets get onto projects...

I already introduced the Airstream...

My push on that, is to replicate this Vacuum formed panel that goes between the bumper and bodywork.... In Aluminum... :lol_hitti

Mine is shot... UV made it brittle, cracked, warped, and a few pieces of it have disappeared already, making the problem worse.

wasfast · Oct 3, 2018

Boy you got a solid, lengthy start on GJ! Really great to see all the restoration work on tools and the Airstream. I read your first paragraph then looked at your location and thought "economical and Orange County?"

Keyblazer · Oct 3, 2018

wasfast said:
Boy you got a solid, lengthy start on GJ! Really great to see all the restoration work on tools and the Airstream. I read your first paragraph then looked at your location and thought "economical and Orange County?"

LOL,
Yeah, 57 yo and out to pasture due to a visual issue....
Trying not to let it slow me down tho!
The above posts are 8 years of hard work, since I became unemployable!

Most of this and more to come has been posted in GJ already, hence the 400+ posts.

Anyway...
This Airstream panel has been testing me...

Tried to form the first panel parts from 0.063" 5000 series taught me about work hardening...

Keyblazer · Oct 3, 2018

Built a buck to try to get the shape I wanted...
Which was different to the OEM part...

Fitting pieces...

Needed to see if what I had in mind might work...

Keyblazer · Oct 3, 2018

My first aluminum sheet metal TiG attempt was "Ok"...
but I burned hole, learned about weld contamination, planishing, and material brittleness!

This was my Mk 1...
Lots to learn, but I was actually pretty pleased with the result/
Despite how lumpy it was, it actually fitted!

Working on Mk 2 which will be different...

Ohmthis · Oct 4, 2018

Keyblazer, you’re a man after my own heart. I grew up poor and having a budget at all (let alone a small one) was tough for awhile while I was going to school. I’m loving all of your projects. Keep posting up!

Keyblazer · Oct 4, 2018

Thanks!

So I realized early on that I needed a Lathe and Mill to do some stuff, I neither had the budget or space for them.

The solution, whilst comprised, was on CL...

An early 80's Shoptask 1720 Lathe Mill Combo.
This was the CL pic.

Drove the 200 mile round trip to snag it and $200 exchanged hands, and there it was, with some tooling, in the back of the car!

Lifting it into its spot...

There was some stuff to repair, setup, and maintenance was done, and it works quite well!

joe49 · Oct 4, 2018

Great job. Will be following your thread.

ezover · Oct 4, 2018

Always amazed at the skills people have on here and those that can do so much with so little. Myself I have ZERO creative bones in me. I can copy and modify but that’s about it.

Will be following your thread also.

Keyblazer · Oct 4, 2018

Made this Radius turning attachment, so I can make cool stuff...

Radius die for the beadroller...

Which gave me this turned edge on 0.063" aluminum for the Airstream panel...

Keyblazer · Oct 4, 2018

ezover said:
Always amazed at the skills people have on here and those that can do so much with so little. Myself I have ZERO creative bones in me. I can copy and modify but that’s about it.

Will be following your thread also.

Dont agree with you...
To take even someone else's idea and copy it requires skill...
Making anything is not easy...
The fact that some people here make it look easy, comes from practice, and with practice comes polished skill.

My Old Training Manager had a great phrase, which is very true.
"A man that never made a mistake, never made anything."

Keyblazer · Oct 4, 2018

Let me give you a perfect example...

I had never used an English wheel.... My skill set is not metal, altho I had basic skills from school shop and an apprenticeship.

When I bought my E-Wheel I knew its a difficult tool to learn.
The first time, I was horrible... I could not get my muscles to do the incremental move each pass that gets a constant curve... but I kept at it and now I am at maybe 20% skill level, and can do basic curves...

An example would be something I did a couple of weeks ago...

Someone on the Airstream Forum crunched their motorhome roof.

I suggested if the panels were removed, it could be wheeled out...
But I was not sure...
So I decided to do a test panel to see if I could do it...

Keyblazer · Oct 4, 2018

Started with a 24" square of .040" 5052 Aluminum.

Minumal pressure, with the largest lower curved wheel I have..

Wheeled it in one plane... Note my wheel tracks are better but not perfect.

Then went the other way.

Keyblazer · Oct 4, 2018

Was happy that the test panel was similar to the curve on the Airstream.

So I threw a 20" length of heavy 2.5" square trail hitch receiver on it... :headscrat

3 times... to get the dent and crease I thought was indicative...

Keyblazer · Oct 4, 2018

Then got after wheeling it back out...

kazlx · Oct 4, 2018

Nice job. Get after it! I'm in Tustin if you need anything. I have a small VMC in my garage among other things.

Keyblazer · Oct 4, 2018

kazlx said:
Nice job. Get after it! I'm in Tustin if you need anything. I have a small VMC in my garage among other things.

Oh Wow... I just read page 1 of your stuff... gonna have to dig in deeper!

Nice!

What's going on in my little Garage....

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