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Kaiserjeeps 04-04-2019 07:21 PM


Originally Posted by Frank Ziebert
Al I need to start printing your post for reference!

My steering wheel is repaired and ready for paint. I know you told us what you used but I cant find that post--even using search. Do you remember what it was and are you satisfied with it?

I just went and looked. I don't have the can anymore. I am just about positive it was a SEM paint for plastics. I still have the SEM prep spray.. So I am sure it was SEM. I pretty much post everything I do, I would bet it is posted way back when I built the column the first time. It would be last year or the year before.
Since it has been 9 years now... It could even be the year before that.;)
Sorry I am not much help. But it was a SEM black paint for plastic.

Kaiserjeeps 04-04-2019 07:50 PM

Spring is officially here! I got my first knat bite right in the small of my back. :thumbsup:
So I found a 14 dollar little oven at Goodwill. It was perfect for testing my vinyl patterning using heat. The oven is a nice little unit, but inaccurate as heck. I picked up an oven thermometer and I was shooting the metal with a digital temp gun since it was never what the air temp was inside the oven at the time.
I figured about 175 degrees would do it. Not even close. Nothing exciting happened till I hit 250 then 280 and 300ish. Then it started doing something.
I messed around with temps, time on the vinyl, and tried some clamps.

It took a while. 175/20 means 175 degrees and 20 seconds on the vinyl

This is what I am looking for. I can tell that mass and how fast it cools matters. The ribbed aluminum started to cool as soon as I grabbed it. It needs to be bonded to a thick piece of metal to keep the heat. Anyway this is super close to what happened at the factory.

This is all the hot and cold results so far. I am not really pleased with much of it. I will keep on it.

I will go ahead with the metal stamps. But this is going to require a LOT more work to produce something worthy. So I finished all the interior panels. I am also cutting back the 4 sample panels from the water jetter to fit the original shrunken vinyl for all 4 doors. They won't fit perfect but they will sure do for a driver.

Everything got sealed with wood hardener and carefully drilled for panel clips.

I cleaned up all the clips and brackets. Then sealed them with clear coat to keep them from corroding later. Using a surplus of rivets from the front door division bar repairs, I found they were the same basic rivets.

There is a lot of them. The clips for the removable panel. They look bent to me. But they were not. All of them I had on various panels were exactly like this.

Everything fits like a glove. Everything is ready for vinyl. I still need to find the two dash pad style wire clips for the front edge. I have 2 but need 4.
The 2 I have are rusty. I will send them through the bucket full of must for rust and paint them. I also want to emboss the vinyl with the bars that are on these panels. I need to figure that out before attaching the vinyl on these back panels. Never a dull moment.

The wheel houses will get black carpet. They both came in the kit grossly oversized. I will trim them back and get it all to fit.

I reglued the loose foam on the old door panel skins this evening. I should be able to attach the old vinyl to the new panel boards tomorrow. I will need an extra set of hands for that. My wife is helpful.

The passenger side rear removable panel that has the 7/8th ID nickel plated grommet for your finger was just about impossible to find. All grommets have flanges that are way to big. After hours of looking I found 7/8ths nickel plated candle holder of all things. They resemble the factory part almost perfectly. I will have to trim back the backside and probably make a crimping die on the lathe for it, but that's half the fun right? I ordered a bag of 10 the smallest I could get. We will see how that one goes.

**************>>>Million dollar question<<<*****************

What was stored in behind that rear removable panel? A jack and tire iron?
I have never known with all the wagoneers I have been through. Nothing has ever been in there but rust and dust and housing for mice.
Anybody know?

SJTD 04-04-2019 10:57 PM

My '84 had the jack in there. I don't know if there's supposed to be some kind of holder for it.

Kaiserjeeps 04-05-2019 01:50 PM


Originally Posted by SJTD
My '84 had the jack in there. I don't know if there's supposed to be some kind of holder for it.

It seems like the stuff in there could dent the outer skin. So a mount would not have been hard to mass produce and spot weld in. But it is a Jeep right?:D

Kaiserjeeps 04-05-2019 03:59 PM

Sometimes I love the internet. It took me about two hours of late night searching to find these. Of all things, candle stick holders bought from a cigar box guitar shop! For the back removable panel. A little work to secure them, but I would call this a score.:thumbsup:

A 7/8ths hole saw and it fits perfectly.

If I could only get so lucky on the door panel chrome trim extrusion. That has been a tough one. Both for standard and deluxe panels. No one seems to make anything like it anymore.

Towtruck 04-05-2019 04:13 PM

Have you seen the rubberized door card material? It's sort of fibrous like the stuff you're using, but it's impregnated with something like rubber. I had to have a door panel resized for my Jaguar project and the trim company (OSJI in Muncie, Indiana) sent me a new card made from this material. Much better than the traditional fiber board in my estimation...waterproof for starters. You might call them and ask about it...maybe a number for their supplier. Nice people. (And I'm going to need a new set of front door cards for my pickup).

Kaiserjeeps 04-05-2019 10:06 PM

I have not heard about that. I will have to check it out. Now you have me wondering. I used an acrylic impregnated panel board (that accepts water) and then sealed it with wood hardener. Ideally this should waterproof and seal the board. At least that is what I have been saying about it. So now I need to seal a sample of the same panel board and get it wet. Completely soak it. I will post the results.

The other thing is all the work in creating a very accurate reproduction of the door panels means I want to use what I have invested in. It has taken a lot of work to get the help from my cousin to draw up the file for the water jet. Then to wade through the corrections and run several sets. I am still real curious about rubberized door panels. I will have a look see. But if the sealed panels I am making resist water, I will be selling blank panels so jeep owners can top them with what ever suits them. Just today I was wondering if I will need to stick plastic on the door before the panel. Like the factory did. The panels I am getting cut will fit exactly like originals on the earlier rigs. So keep that in mind later when you want to replace your truck panels. I believe the wags and J trucks take the same panel.

EDIT: I was wondering how they knew what size to make your door card. I get it as they are a specialist in Jags. Nice looking place and high quality work.
Original Specification Jaguar Interiors. :D

Towtruck 04-06-2019 08:15 AM


Originally Posted by Kaiserjeeps
EDIT: I was wondering how they knew what size to make your door card. I get it as they are a specialist in Jags. Nice looking place and high quality work.
Original Specification Jaguar Interiors. :D

I removed the vinyl trim on the original panel in the kit, then transferred the original outline and all the hole locations of the card to a sheet of brown paper. Then I carved the panel until I had an exact fit. The new outline and hole locations were transferred to the same sheet of brown paper, which was annotated with copious notes...arrows, etc. So I had a before and after overlay of exact positions for everything. I sent the paper to OSJI and they made a new panel in that "rubberized" material and returned it overnight charge. They even included a new piece of vinyl, since the holes had moved. Again, great call them and let them know you were referred to them by a very satisfied Jaguar customer. They'll help you out. I think you'll be pleased with the card material. (I'll purchase a new set of front door cards in either material, but would prefer the black impregnated stuff if you can make it work).

IMG_5033 by Rufus, on Flickr

SJTD 04-06-2019 08:59 AM

I think you still want the plastic. It's there to keep water in the door so it goes out the drains.

Even if you have a waterproof card water may still get on it. It'll run down and get under the edge of the upholstery or run down the inside of the door.

Even if it doesn't soak into the card it doesn't seem a good thing.

Newer vehicles with formed ABS cards still have the plastic.

Kaiserjeeps 04-06-2019 12:19 PM

Very important points SJTD. It will get plastic.

Towtruck, thanks for the info on the door cards. I looked for information on the rubberized cards and could not find specific info on them. I did get to check out the site and see some cool stuff.
That is a stunning Jag. I bet it is a pleasure to drive. It reminded me of the old movie Harold and Maude. One of my old favorites. I have read up on your build thread. Very cool work. Flat black is unforgiving and your work is really nice looking.

Frank Ziebert 04-06-2019 07:26 PM


Kaiserjeeps 04-18-2019 10:52 PM

I am having to resize every single picture despite my camera being on the correct setting. It makes posting pictures of every single nut and bolt difficult to say the least. ;)

I promised Bill I would post these tonight. Tomorrow is his birthday, so Happy Birthday Bill. :thumbsup: I have a wagoneer for you. Well almost. In about two months maybe....

I have been a busy dude. Juggling chainsaws. Where to start. In response to adding plastic to the doors before panels which they WILL get, I dipped a piece of door panel material sealed with wood hardener in water for 30 minutes. It fared extremely well. It is not something I would do with a door panel, but with plastic the panels I will be making will do fine. Far better than factory panels. The top one inch is uncoated and soaked up water.

Moving onward.. Two steps forward and one step back. Stuff happens... I wanted to glue the original door vinyl on to new panels. To at least get something on till I can build new panels from scratch. The top half of the vinyl is the exact same material as on dash pads. A grained plastic vinyl. Very brittle with no heat on it. The lower section below the trim strip is conventional vinyl. Using a new contact adhesive I coated the door card and the back side of the door panel with glue. I left the foam on the door panel.
To my horror the glue started to dissolve the upper section. I left the thin foam on and there was to much glue that did not dry right away, it made a huge mess.

Door panel varicose veins. This is what happens when you get old.

Ugh... I peeled it off the board quickly before the glue set up firm. I am fortunate that this was an extra. I had a second choice and switching to fast tack 92 I was able to get the next panel glued down OK. I learned that I should have removed the old factory thin foam as it keeps glue wet and that is not good.
I will NOT have this problem using the newer vinyls I will be using to make the new door panels. That will be all vinyl and made for these glues. None of the plastic grained stuff. So this problem will only exist with old style panels.
Tomorrow my wife and I will do the remaining three doors. Cross yer fingers.

I have been racking my brain on what to use or make for an oven. To heat up stamps for door panel vinyl. I have been searching Craigs List every day looking for something that would work. Well I bought a used small aluminum truck box. It is perfect for the shape I need to do this.

I will line it with a stainless steel smaller box I will form up from a sheet of stainless Bill gave me. I picked up some high heat ceramic insulation to surround the SS interior box. I have been thinking about this when I sleep. And when I am awake. :D

I am thinking a dual burner electric hot plate mounted under the box with a couple holes for each burner. I have been looking for a used one. I had my eye on stoves on CL but I don't think that is the way I am going with this.

In the mean time, I have been making or starting on the metal stamps.
Not finished yet, I need to weld it up. Here is the stamp for the back removable passenger side panel. I will have three different stamps for the whole back end of a wag. The metal for the impression is cold rolled steel. Completely square edges and no mill scale like hot rolled would have. Hot rolled also has a crowned edge. It would not leave a desirable pattern. Cold rolled is very smooth. The angle iron is hot rolled. Mill scale all over it.

While all that is under way, I have been trying to finish the last details. Getting in materials to finish several things. This is the sleeve holder for the rear seat that hooks on to the mushroom head bolt half way up the passenger side door pillar. I just wanted to replace the bungee. I still need to build it and wash the heck out of the rest of it. I hope to make these also.

The ever elusive rear seat holder strap.

Chainsaw number 4...:D

I needed to finish the hood latches. I wanted to take them all apart but that meant new pivot shafts because I had to destroy the old shafts by drilling the swedge out. So I picked up a 2 foot piece of 5/8 304 Stainless and made new ones.

Dirty and disgusting and not worthy.

New shafts. These took way to long to turn down. I had cooling air on the parts while turning them down. To much heat on stainless and we all know what happens when you try to drill or machine stainless after it gets hardened.

After a long scrub in the solvent tank and a quick pass through the bead blasting cabinet, I coated everything with Cerakote satin nickel C 124. It looks close to zinc plating. At least everything under the hood matches.
The springs got MC160 clear. That stuff is so tough. I welded a SS washer on the ends of the shafts to hold it all together. Cerakote is high heat capable and it did not phase the finish at all. Paint would have burnt from the brief heat made from welding. Plus I squeezed it with a clamp to get the post to stick up to keep the heat away from the frame. It worked well. No heat damage.

I was satisfied with the result.


The hood now closes and latches like it should.

I covered the sail panels for the rear pillar with new vinyl. I forgot to take a picture of them installed. They also look great.

The varicose vein look on the door panel has dried and it shrunk back up pretty well. It might be usable still. Hopefully I will be able to get the remaining door panels on without to much trouble. I will post up after I get the chrome overlay on the trim. Hopefully it will look good.

Frank Ziebert 04-19-2019 09:35 AM

Those latches are fantastic!

Kaiserjeeps 04-19-2019 10:27 AM

I will have the pictures we talked about for you this morning. Yesterdays stuff took longer than anticipated. Sorry about the delay.

Frank Ziebert 04-20-2019 10:09 AM

Not a problem. Got them and it was exactly what I need to see. Thanks a million.

Kaiserjeeps 04-20-2019 11:00 AM

No sweat Frank:thumbsup:


Working with used door panels is a waste of time. They are kicking my butt. All I wanted was something good enough till I can make new ones. The rear door has blistered, the chrome tape will not stick no matter how many times I wipe it down, and they look like pooh. I spent 4 hours peeling existing foam and the glue off that I attempted to secure on each panel. Before gluing them down. I may try spraying with a new bright silver cerakote I just got in. Hopefully it won't orange peel or fish eye. The 303 year long soak is now not my friend.
The crappy looking panels are flat as ever. That is the only bonus it seems.

I need to get new ones done. Many of the issues will go away with new materials. I am confident of that. I will keep building the oven.
I'm going outside to play...

Frank Ziebert 04-20-2019 06:17 PM

Nothing kicks your butt. Might slow you down a bit but WTH.

Kaiserjeeps 04-25-2019 10:06 PM

Well still putting small items on. Nothing worth posting really. I have been collecting everything for a truck box oven. I believe I have everything here now. Today I picked up a candy thermometer to poke down into the top for my basic temperature indicator. I also have a 220 AC dual 8 inch coil hot plate for a heat source with infinite heat control here now. I found a power adapter to fit my 220 welding receptacle that converts to the odd plug on the hot plate. I am waiting on it. Today I also picked up all my door panel pattern drawings from my cousin. I need to take them into Spokane and have the water jet company guy convert them to files for the water jet. Then cut out a front and rear set.
I meet with him tomorrow at 2.

In the mean time I have a large pile of materials here for the oven. I am starting on the fabrication this weekend. I am investing a lot into this. I will hold on to my confidence that it will work. One really nice set of door panels would be great. 10 sets later on would be even better. I am still trying to get stuff done on the wagoneer while all this is taking place. I keep waking up at 4AM. I wish that would stop. :rolleyes:

Frank Ziebert 04-26-2019 12:43 PM


Originally Posted by Kaiserjeeps
I keep waking up at 4AM. I wish that would stop. :rolleyes:

Sure glad I am not the only one!:thumbsup:

jaber 04-26-2019 08:00 PM


Originally Posted by Frank Ziebert
Sure glad I am not the only one!:thumbsup:

Damn, that makes 3. I don't feel so bad now. Haven't slept past 6 am in many years.

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