In Automotive Bodywork and Rust Repair, veteran Matt Joseph shows you the ins and out of tackling both simple and difficult rust and metalwork projects. This book teaches you how to select the proper tools for the job, common sense approaches to the task ahead of you, preparing and cleaning sheet metal, section fabrications and repair patches, welding options such as gas and electric, forming fitting and smoothing, cutting metal, final metal finishing including filling and sanding, the secrets of lead filling, making panels fit properly, and more. Also included is a comprehensive resources guide.
There comes a time when just about every car on the road will need some form of rust or body repair. Quite often, if the car is a daily driver for running errands, repairs are never made, and the car eventually ends up in junkyard heaven. For our beloved collector cars, hot rods, and muscle cars, dents, dings, and rust are not an option, and neither is the scrap heap. And for just about any restoration project, the bodywork is by far the most expensive part of the process. In Automotive Bodywork and Rust Repair, veteran restorer Matt Joseph shows you the ins and out of tackling both simple and difficult rust and metalwork projects. This book teaches you how to select the proper tools for the job, common-sense approaches to the task ahead of you, preparing and cleaning sheet metal, section fabrications and repair patches, welding options such as gas and electric, forming, fitting and smoothing, cutting metal, final metal finishing including filling and sanding, the secrets of lead filling, making panels fit properly, and more. Also included is a comprehensive resource guide.
Whether you decide you want to tackle a full restoration project, or just want to save money by doing minor repairs yourself, Automotive Bodywork and Rust Repair is the book to get you through it.
A history professor by trade, Matt Joseph's automotive passion was inherited from his father early on. Matt has been published in more than 1,800 feature articles, and was a contributing editor for magazines such as Skinned Knuckles and Cars & Parts. He has hosted two automotive themed radio talk programs, and presently works in TV. He continues to work as an industry consultant, providing services to corporate, financial, and government clients on various aspects of automotive design, marketing, advertising, publications, and policy.
Acknowledgments Introduction Chapter 1: What You Should Know Before You Start Panel Types, Configurations and Reinforcements Autobody Steel Plasticity and Elasticity Work Hardening: The Metal Remembers At the Factory and Afterward Necessary Tools and Equipment General Considerations Chapter 2: Limits of Materials, Equipment and Skills Inherent Advantages Divide and Conquer Chapter 3: Types of Jobs Damage Repair Small Rust Repairs Small Patch Piece Welding Methods Chapter 4: Cleaning, Modeling and Cutting Preparing and Cleaning Sheetmetal Cutting Panel Materials Getting Shapes and Contours Right Chapter 5: Forming, Fitting and Smoothing Simple Tools and Equipment Applying Plasticity/Elasticity, Work Hardening and Annealing Hammering Techniques that Work Bending, Beading and Prying Power Forming Pulling Approaches to Moving Metal Smoothing, Stretching, Shrinking and Forming Operations Chapter 6: Bumping to Move the Metal the Right Way Chapter 7: Metal Finishing Indicating, Feeling and Other Human Tools to Determine Panel Surfaces Filing Done Right The Art of Pick Hammering The Disc Sanding Alternative Chapter 8: Welding Body Metal Types of Joints Welding Smaller Pieces into Large Constructions Fixturing Electric Welding Chapter 9: Filling The Secrets of Lead Work The Project Applying Lead Filler Material Applying Plastic Fillers Chapter 10: Special Projects and Procedures Fabricating a Splash Shield for a Ford Amphibian Making Panels and Trim Fit Quarter-Panel Replacement Door Re-Skinning Hanging Doors Mounting and Adjusting Trim Chapter 11: Before You Paint The Danger from Behind Chapter 12: Minor Rust Repair to a Fender Edge The Approach The First Step: Evaluation Removing the Bad Metal Planning and Modeling the Repair Cutting and Forming the Metal Patches Final Fitting Welding Considerations Cleaning, Positioning, Fixturing and Welding Grinding the Weld Beads and Shrinking the Bulged Area Final Steps before Filling Tinning Applying the Lead Filler Shaping the Lead and Finishing the Job Chapter 13: Repairing Collision Damage in a Decklid The Approach The Early Steps Metal Finishing Filling Chapter 14: Sources and Resources Local Sources Non-Local Sources Knowledge and Problem-Solving Resources Appendix Soldering Data Colors of Steel at Different Temperatures
Teaches you how to select the proper tools, preparing and cleaning sheet metal, section fabrications and patches, welding options, forming fitting and smoothing, cutting metal, final metal finishing and more.
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