PNW_Steve's 2002 Bluebird A3RE

[TrailLifeBill]

Originally Posted by brokedown

Steve, I used my air chisel on a few exterior rivets. It was doing a great job briefly and then the chisel bit started deforming. I grinded it back to a point and heat tempered it again and after 2 more rivets it was deforing again. So now I'm back to the drawing board for those!

I've used the air chisel for several hundred of my interior rivets, and then resorted to a 2 lb hand sledge with a stout hand held chisel (with hand guard - ~$4 at HF). I found that with about 3-4 blows at a very shallow angle, I can pop off the tail of my exterior rivets where they are accessible. Then I use a small punch and the head pops right out.

[PNW_Steve]

Originally Posted by brokedown

Steve, I used my air chisel on a few exterior rivets. It was doing a great job briefly and then the chisel bit started deforming. I grinded it back to a point and heat tempered it again and after 2 more rivets it was deforing again. So now I'm back to the drawing board for those!

I tried my air chisel and trashed the profile on the chisel on the first rivet. Sharpened it and tried again. I wound up with most of the head removed and significant damage to the rub rail.

Either I have a really puny air chisel or particularly hard rivets.

What I have found to work a bit better for me is, where I can reach them, grinding the back side of the rivet and knocking it out with a punch and BFH.

[PNW_Steve]

Originally Posted by TrailLifeBill

I've used the air chisel for several hundred of my interior rivets, and then resorted to a 2 lb hand sledge with a stout hand held chisel (with hand guard - ~$4 at HF). I found that with about 3-4 blows at a very shallow angle, I can pop off the tail of my exterior rivets where they are accessible. Then I use a small punch and the head pops right out.

I will give that a try.

My interior rivets came out pretty easily with an air chisel.

[PNW_Steve]

Getting the rivets on the front cap ground just flush. I am trying to follow Elliot's method:

[brokedown]

I'm seriously considering building over the exterior rivets instead of removing them at this point!

[PNW_Steve]

Originally Posted by brokedown

I'm seriously considering building over the exterior rivets instead of removing them at this point!

That is where we are headed with the front cap.

Grind the heads of the rivets flat and leave them. Then drill new holes between the abandoned rivets for the new ones.

I have managed to get almost all of the rivets out that need to be removed from the sides to accommodate the new skin.

[brokedown]

Steve you need to update!

[PNW_Steve]

Weather has kept me from making much progress.

Today is sunny and warm. As soon as I get some yard chores done I will be back at it.

I spent some time on Thursday measuring for roof raise materials. It looks like I will be using 1" square tube and 3/16" flat stock to shim it to fit. The inside dimension of my hat channel is 1.21".

[PNW_Steve]

I have ground the remaining rivets on the front cap down and ordered material for the roof raise.

Weather is awesome and I had hoped to be ready to begin the roof raise on Friday.........

Weather forecast for Friday & Saturday.... Showers and wind.....

[brokedown]

Rain rain go away!

[PNW_Steve]

Originally Posted by brokedown

Rain rain go away!

Hmmmm..... You apparently have more pull than I do....

Today's version of the forecast has sun on Friday with wind and rain starting late in the evening.

Off to pick up steel, 6 ton jack stands, cutoff wheels and a few other goodies.

[PNW_Steve]

Thing are starting to happen here.

Weather turned nice and Asetechrail volunteered to give a hand. What a Godsend!! I would be in way over my head without his help.

Asetechrail built the jack mechanisms and brings the metal fabrication skills into the project that I am sorely lacking.

We worked together to figure out a plan for the roof cuts. Well... It was probably more like 3-4 plans before we started cutting.

Ok..... I was going to place a picture and the comment on it. I am not finding the right way to do this so Here are pics of:

The jack mechanism
Welding and grinding the inserts for the raise
Cut lines on the front cap
Cutting the front and rear caps

[PNW_Steve]

Continued:

[PNW_Steve]

Regarding the hat chanel inserts.

First, I have some bad news for MuddaEarth: the 1-3/16" square tube that you used for your roof raise does not exist so your roof is probably going to fall off... According to the local metal suppliers there is no such thing. " I have been doing this for 40 years and have never heard of 1-3/16" tube" said the last guy I talked to.

So, we decided to take 1" square tube and weld 3/16"x1" flat stock on the side of it to make our inserts. It is working but is taking WAY too much time to weld and grind each piece.

I am going to call and get a quote for having some C-channel bent up on Monday.

I have to say again how much I appreciate the help I get from this community and especially Asetechrail for his help. He is a Rembrandt with the angle grinder. I am more of a Picasso.

[dan-fox]

I hear you. I'm a Jackson Pollack sort of guy with metalworking.

[PNW_Steve]

Looks like we are going to scrap the "built up" hat channel inserts in favor of custom bent C channel.

Just got a quote from the fabricator. Less than $10 each. They will be ready on Thursday.

Roof raise on Friday!!!

[PNW_Steve]

I tried to get some better pictures of the cuts so far. I hope they show a little more detail.

I also started on cleaning up the interior wiring. For some reason the pics are all black... I will try again later.

As I mentioned earlier, we have scrapped the idea of shimming 1" square tube with 3/16" flat stock to fit the 1-3/16" opening in the hat channel for our roof raise. Instead we are having custom C channel bent up to fit. It is supposed to be ready tomorrow and plans are to get the roof lifted on Friday.

Pray for no wind!!

[EastCoastCB]

Love seeing the build pics! Are you cutting across any windows or just going high?

Nice to see YOU in the pics, too. I like having a face to go with folks on here!

[PNW_Steve]

Originally Posted by EastCoastCB

Love seeing the build pics! Are you cutting across any windows or just going high?

Nice to see YOU in the pics, too. I like having a face to go with folks on here!

Thanks!!

We are cutting the line along the front cap that will hit near the top of the first side window then all of the remaining side cuts will be near the middle of the window openings.

As the rear cap is damaged we are cutting most of it out and framing a near flat spot that will not be raised to accommodate the outdoor portion of my mini-splits.

The raise will be from the first bow forward of the rear cap all of the way to the front cap. Pretty much raising all but the rear 30".

To give you a rough idea:

[EastCoastCB]

Very cool. Love the idea for the location in the rear for the mini splits!