Author Topic: Challey Header Repair ?  (Read 1325 times)

Offline Bullitt-

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Challey Header Repair ?
« on: April 13, 2008 - 09:52:35 AM »
Damage to the header, pictured below, is about 1/2" deep 1/2" tall 1/2" wide....What  products would you recomend to use to make this repair?

Thanks Wade

 
Wade  73 Rallye 340..'77 Millennium Falcon...13 R/T Classic   Huntsville, AL
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Offline NoMope Greg

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Re: Challey Header Repair ?
« Reply #1 on: April 13, 2008 - 12:23:24 PM »
New ones!   :22yikes: :poopoke: :roflsmiley:
Greg
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Offline MEK-Dangerfield

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Re: Challey Header Repair ?
« Reply #2 on: April 13, 2008 - 01:07:49 PM »
New ones!   :22yikes: :poopoke: :roflsmiley:

Good one!!   :smilielol:


Wade,

    Is this fiberglass? I remember someone doing some type of repair to mend a Cuda grill. I can't remember who though.  :banghead:



  Mike

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Offline Bullitt-

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Re: Challey Header Repair ?
« Reply #3 on: April 13, 2008 - 01:13:27 PM »
Greg.....find me a new one & I'll buy it...................................I'm waiting  :walkaway:


Mike, Does seem to be fiberglass, nothing like the thin plastic repairs on the grills.... My 1st thought was to load it up with filler but I figure that will crack or break loose...I've also thought about embedding metal mesh to give it strength, that's probably overkill.....Then what seems to make the most sense would be a fiberglass repair kit but I wonder if there does not need to be some more reinforcement.  :dunno:
Wade  73 Rallye 340..'77 Millennium Falcon...13 R/T Classic   Huntsville, AL
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Offline dutch

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Re: Challey Header Repair ?
« Reply #4 on: April 13, 2008 - 01:22:12 PM »
hey wade
could you post a pic taken a little further away...
I work at a companie that builds trikes and sidecars. There is one guy who has been working with glass for almost 40 years...I can show him the problem tomorrow and let you know what would be the best way to repair.

let me know,
Bart
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Offline MEK-Dangerfield

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Re: Challey Header Repair ?
« Reply #5 on: April 13, 2008 - 01:25:34 PM »
NO Bondo, that's pretty much all the advice I can give at this point. Any vibrations or anything, and it will eventually show a crack. I have that problem where the fiberglass hood scoop meets my steel hood.   :pullinghair:


  Mike

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Offline Bullitt-

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Re: Challey Header Repair ?
« Reply #6 on: April 13, 2008 - 01:43:29 PM »
hey wade
could you post a pic taken a little further away...
I work at a companie that builds trikes and sidecars. There is one guy who has been working with glass for almost 40 years...I can show him the problem tomorrow and let you know what would be the best way to repair.

let me know,
Bart


Bart...That will be great!!!.. The backside is hollow so I could get a lot of strength there.

Thanks Wade




Wade  73 Rallye 340..'77 Millennium Falcon...13 R/T Classic   Huntsville, AL
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Offline dutch

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Re: Challey Header Repair ?
« Reply #7 on: April 13, 2008 - 02:04:50 PM »
okay, I`ll let you know tomorrow what he thinks.  Do you perhaps have a pic of the other side , which is intact?
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Offline Bullitt-

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Re: Challey Header Repair ?
« Reply #8 on: April 13, 2008 - 02:11:13 PM »
I'll get some...give me a few min.
Wade  73 Rallye 340..'77 Millennium Falcon...13 R/T Classic   Huntsville, AL
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Offline Bullitt-

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Re: Challey Header Repair ?
« Reply #9 on: April 13, 2008 - 02:23:34 PM »
Good side


Wade  73 Rallye 340..'77 Millennium Falcon...13 R/T Classic   Huntsville, AL
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Offline 422STROKER

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Re: Challey Header Repair ?
« Reply #10 on: April 14, 2008 - 07:51:38 AM »
From the little fiberglass work I have done, it is pretty strong by itself when cured. :2cents:

Even the filler with fiberglass in it is pretty good too.

Tom :2thumbs:
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Offline dutch

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Re: Challey Header Repair ?
« Reply #11 on: April 14, 2008 - 12:34:54 PM »
hey Wade,

sand front and backside with grit 60 or so about 3"around the damage.  Drill some small holes 2"around damage.  shape and tape or glue a piece of sheet alu to the inside of fender. start laminating the glass with the resin on the outside with small pieces first roughly in the shape of the damage. Build up layers till you have the thickness you need. later you sand down the areas around the damage to the right level. when done, let it dry and do the same trick on the inside after removing the sheet metal. Sand the hole thing back into shape and it will never crack again.
just use a paintbrush to press the air out of the resin.
I hope this makes any sense to you...if not, you know where to find me...
good luck

*** Bart ***

Offline Bullitt-

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Re: Challey Header Repair ?
« Reply #12 on: April 14, 2008 - 01:46:40 PM »
I dig it dutch.  :thumbsup:    Thank you ...& Thank your friend for me.

Wade
Wade  73 Rallye 340..'77 Millennium Falcon...13 R/T Classic   Huntsville, AL
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Offline 73EStroker

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Re: Challey Header Repair ?
« Reply #13 on: April 14, 2008 - 10:51:37 PM »
I repaired my 73 front end with more damage than that by using Epoxy fiberglass resin (not polyester, vinylester anything ..ester) and medium filler cloth.
1. Clean the hell out of the part to be repaired and cut some pieces of cloth just over the size of the repair required.
2. Lay some resin down with a brush. Not too much at a time.
3. Then cut small pieces of cloth and lay one bid (layer) of cloth over it.
4. Nice soft strokes of the brush with more resin on it to get the cloth to lay down flat. Keep the brush wet with resin.
5. Poke at it a bit with the brush as you must get the air bubbles out.
6. Keep filling out with resin and cloth if you have to extend the repair past the original part but look at the cloth weaves, you will see how it is oriented and place the weave 90degrees to the first cloth install. Don't put too much on at once, wait 12 hours before doing it again.
7. Once you have your shape you can sand the resin and cloth down with coarse sandpaper then go the bondo route.
8. If the skim of bondo is light (IE you did a good fill job with Epoxy and cloth) you will never have a problem with cracking.
9. Also put one layer on the backside to offer some more strength - the spot where your picture shows it a little crummy.
10. Remeber keep it thin in case you apply another layer.

Hope this helps. It worked on my car and has worked on my airplane for 4 years now and that thing sure vibrates way more than a car and zips around at 180-190 mph in cruise and no cracking.
Barry (Salmon Arm)