|The Forward Look Network|
| "Make-Up" your Car!|
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|Forward Look Technical Discussions -> Body, Glass, Interior and Trim||Message format|
Cap MIRROR CONTROL: I found a remote mirror set with the cap MIRROR CONTROL, didn’t see before and missing in my car (01). When arrived it showed scratched and too wasted, couldn't repair better (02). I had to remake another cap.
First model in 3D-RealView with engraved letters (03) (04), then 3D-Print in black, fill the letters in white (05) and hook up on the nut (06).
Now the heavy chrome has reduced somewhat, the aspect more appealing (07). - SERGE - ;)
N.B. The cap was printed in FDM-Technology. Will redo in SLA-Technology for much higher accuracy of the engraved letters. When done I will replace and present here.
Edited by sermey 2022-10-09 12:04 PM
(01 Remote Mirror Set.jpg)
(02 Cap MIRROR CONTROL OR.jpg)
(03 Cap MIRROR CONTROL CAD.jpg)
(04 Version Smaller Center CAD.jpg)
(05 Painting Letters on 3D-Print .jpg)
(06 Cap Hooked up.jpg)
(07 Final Front View.jpg)
01 Remote Mirror Set.jpg (102KB - 99 downloads)
02 Cap MIRROR CONTROL OR.jpg (57KB - 93 downloads)
03 Cap MIRROR CONTROL CAD.jpg (95KB - 96 downloads)
04 Version Smaller Center CAD.jpg (69KB - 85 downloads)
05 Painting Letters on 3D-Print .jpg (90KB - 90 downloads)
06 Cap Hooked up.jpg (86KB - 89 downloads)
07 Final Front View.jpg (118KB - 93 downloads)
Replacing the Windshield (Add-on): On special request here the full picture (05).
(05 All New Green Tinted Glasses.jpg)
05 All New Green Tinted Glasses.jpg (236KB - 90 downloads)
sermey - 2009-01-04 1:02 AM
Rear Lamp Gaskets: No comments to the old / original Gasket.
I found High Precision Hydraulic Rings, self-centering inside, outside not overlapping at all, and they fit as tailored. The black Height of 1/4" is a nice separation between the White Body and the Rechromed Housing.
Another inconspicious "Make-Up". :)
Rear Lamp Gaskets Data Sheet: This High Precision Hydraulic Ring is no more available from the supplier. I found a similar Data Sheet as information (01) from another manufacturer.
The costs are quite high for a gasket, as it needs 4 items for a 1959 Dodge. On the other hand this material is more durable than any rubber.
The CAD design shows how the lip sets in center position of the housing (02), and how accurate this profile fits in size (03).
Mounted on the car there is a decorative distance of 6mm (04). By tightening, the outer surface of the ring becomes slightly rounded, a desirable effect (05). - SERGE -
(01 Abstreifer Datenblatt.jpg)
(02 Rear Lamp Gasket Profile CAD.jpg)
(03 Rear Lamp Gasket CAD.jpg)
(04 Rear Lamp Gasket on Car.jpg)
(05 Rear Lamp Gasket on Car Zoomed.jpg)
01 Abstreifer Datenblatt.jpg (131KB - 85 downloads)
02 Rear Lamp Gasket Profile CAD.jpg (51KB - 91 downloads)
03 Rear Lamp Gasket CAD.jpg (75KB - 88 downloads)
04 Rear Lamp Gasket on Car.jpg (179KB - 85 downloads)
05 Rear Lamp Gasket on Car Zoomed.jpg (159KB - 90 downloads)
Convertible Top Down: Most Convertibles shows not correct setting of the top when down. Even on perfect restored cars of our challenging members (01) (02), the heighted top stands out, up to 10cm (03). This reminds the old fashioned “carriage” look on convertibles of earlier years (04).
Before restoring, the top arm of my car was as well up (05). With some effort I adjusted the mechanics for fully entering in the side box. The end of the arm now touches the body, as it should be (06). View from side, camera horizontal lined to both door borders, the top arm almost disappears (07). Then the top cover is adapted correspondingly to fit. Now it shows very flat (08).
Another harmonic car outline of designer Virgil Exner (09). – SERGE -
(01 Nice Convertible - Gary.jpg)
(02 Nice Convertible - Mike.jpg)
(03 Top not down - Gary.jpg)
(04 Top earlier years.jpg)
(05 My Convertible Before - Top Arm Up.jpg)
(06 My Convertible After - Top Arm down.jpg)
(07 View from Side.jpg)
(08 Flat Top Cover.jpg)
(09 Review the Convertible.jpg)
01 Nice Convertible - Gary.jpg (183KB - 86 downloads)
02 Nice Convertible - Mike.jpg (185KB - 90 downloads)
03 Top not down - Gary.jpg (183KB - 86 downloads)
04 Top earlier years.jpg (128KB - 90 downloads)
05 My Convertible Before - Top Arm Up.jpg (102KB - 83 downloads)
06 My Convertible After - Top Arm down.jpg (117KB - 90 downloads)
07 View from Side.jpg (133KB - 84 downloads)
08 Flat Top Cover.jpg (114KB - 85 downloads)
09 Review the Convertible.jpg (153KB - 86 downloads)
|The difficulty to get the top down completely is a common one. I have installed two soft tops on cars I have restored and both have had this issue more or less. |
I spent a lot of time to adjust and got to the point where I had to enlarge the holes. I think maybe the soft tops are thicker and stiffer nowadays. In my case they
were canvas tops.
You seem to have succeeded in this too Serge.
22mafeja - 2022-10-27 1:50 PM The difficulty to get the top down completely is a common one. . . . . .
You see absolute right, Ralf. I will come back and show some basic points how I did. There are already about 20 years since then. - SERGE -
Edited by sermey 2022-10-28 2:30 PM
Foiling a 1959 Dodge: Original Danis 1959 Dodge was unicolor white (01). Then he foiled his car partly to green (02). Seeing my car live he got very impressed about this combo, so as now re-foiled green to golden (03)(03a). Another golden 1959 Dodge. Congrats to his top-job! He can redo at anytime and to any color if desired.
After getting all knights golden (04), this 1959 Dodge is on the best way to become a noble vehicle - nice to look at. - SERGE-
Edited by sermey 2022-11-07 10:39 AM
(01 Danis 1959 Dodge.jpg)
(02 Green Foiled.jpg)
(03 Foiling green to golden.jpg)
(03a Foiling green to golden.jpg)
(04 Danis 1959 Dodge Front.jpg)
01 Danis 1959 Dodge.jpg (160KB - 80 downloads)
02 Green Foiled.jpg (132KB - 79 downloads)
03 Foiling green to golden.jpg (160KB - 78 downloads)
03a Foiling green to golden.jpg (121KB - 78 downloads)
04 Danis 1959 Dodge Front.jpg (147KB - 80 downloads)
sermey - 2022-11-07 2:28 PM
Foiling a 1959 Dodge: . . . . this 1959 Dodge is on the best way to become a noble vehicle - nice to look at.
And now all done, within 24 hours - what a prospect!! Who shows next Golden 1959 Dodge? - SERGE -
Edited by sermey 2022-11-09 12:06 PM
(Danis Golden 1959 Dodge.jpg)
Danis Golden 1959 Dodge.jpg (119KB - 78 downloads)
Location: Blythewood, SC
|Do you mean a vinyl wrap?|
57plymouth - 2022-11-09 6:15 PM Do you mean a vinyl wrap?
Yes Brian. A Vinyl especial for cars, as applied on many Sport Cars. It is tricky to mount, on curves to avoid scroll must heat somewhat with a Hair-Dryer.
Needs some practical skill, artistic vein and the motivation to go forward. - SERGE -
|I'm a little surprised you haven't tried to run 59 Cadillac tail light lenses, maybe you thought about it, seems to be in the same vein as some of your cosmetic ideas.|
|I had to read this thread from the beginning again...made me humble... |
Which gas springs did you end up with Serge(trunk lid springs)?
And which stroke?
22mafeja - 2023-03-12 9:43 AM I had to read this thread from the beginning again...made me humble... Which gas springs did you end up with Serge(trunk lid springs)?
Gas Spring Length 275 mm Hub 100 mm Force 200 N with Ball Head Ball Joint, Black. Style Name:275|100|200N|Black
This Gas Spring, Ralf, comes in addition to the existing Torsion Spring Bars in the trunk. Check for correct position, then drill and mount. By removing the clips it can easily be
removed and replaced. Good Luck - SERGE -
Edited by sermey 2023-03-12 7:26 AM
(Gas Spring for Trunk.jpg)
Gas Spring for Trunk.jpg (65KB - 59 downloads)
Location: The Mile High City
The flat fold-down looks wonderful
Edited by Lancer Mike 2023-03-12 12:56 PM
Covering the bottom fold: Most bottom folds under the sill plate look messed up, any more when they are rusty. For protection and a nicer appearance it can be coated as I did with a special black adhesive Tape 3M-33 (01). Of course, the other side of the fold must be sealed when coated, as I did with noise reduction panels on all interior surfaces, and as described earlier.
As the surfaces showed very uneven (02), I started another way by grinding the metal peaks (03), and looked for an adequate Silicone Rubber Profile (04). This, filled with black special adhesive sealant, then set on (05). The excess of glue was immediately removed, the car left for a week to dry through (06).
Now, the fold is protected, especially view from side it looks straight and neatly, as it should be all the time (07). Another “Make-Up” on my 1959 Dodge Custom Royal Convertible. - SERGE -
(01 Fold coated with Scotch Tape.jpg)
(02 Uneven Surfaces.jpg)
(03 Grinding the Peaks.jpg)
(04 Silicone Rubber Profile.jpg)
(05 Pre-Setting the Profile.jpg)
(07 Profile Optimized and Fixed.jpg)
01 Fold coated with Scotch Tape.jpg (80KB - 54 downloads)
02 Uneven Surfaces.jpg (74KB - 55 downloads)
03 Grinding the Peaks.jpg (91KB - 57 downloads)
04 Silicone Rubber Profile.jpg (72KB - 52 downloads)
05 Pre-Setting the Profile.jpg (84KB - 58 downloads)
06 Preview.jpg (104KB - 55 downloads)
07 Profile Optimized and Fixed.jpg (93KB - 59 downloads)
Location: Lower Mainland BC
Very neat and clean there Serge. Good job.
I hate (strongly dislike) the equivalent pinch weld on my 56 Dodge. So far I have cleaned and painted it (but still light blue) but I was thinking of painting it flat black to make it visually disappear from the side.
But now I see yours with the rubber covering and I say "Hmm...that looks good", I am re-thinking the black paint thing.
Where did you get the rubber profile, i.e. what was its original purpose? (Where would I look over here in Canada?)
My pinch weld flange (pretty straight but still ugly)
Edited by 56D500boy 2023-03-26 3:09 PM
DaveFs56DodgeRockerPanelPinchWeldFlange_Mar26_2023.jpg (147KB - 50 downloads)
I never doubt Dave, that you have a pronounced sense for aesthetics, recognizing the optical effect . . . . .
There are various suppliers for such profiles. For your car another profile would fit better, check first the thickness of the fold. - SERGE -
just for dimensions, look at page 3
Edited by sermey 2023-03-26 3:16 PM
Location: Lower Mainland BC
sermey - 2023-03-26 12:12 PM
just for dimensions, look at page 3
So I guessing that you used this one:
U-Profil rund EPDM 5,5x18mm U-Profil rund EPDM 5,5x18mm Maagtechnic Artikelnr: 10007460 Vorrätig
The used profile is not shown in the internet. Here a scan from the big catalogue, you will see Art. No. 122157. I think the narrow one Art. Nr. 122195 may better fit to your car.
You will need total up to 5m. - SERGE -
Edited by sermey 2023-03-27 5:40 AM
U-Profile 150.jpg (196KB - 50 downloads)
U-Profile 150.pdf (200KB - 59 downloads)
Checking the Fuel Pump: As shown earlier, in my car I have two fuel pumps, one original mechanic and a second electrical, switchable. After about 30 sec activation of the electrical Fuel Pump, the glass fuel filter (01) becomes full, can even hear the lower speed of the pump. Now the car will start up immediately. This the main advantage.
The two pumps work in parallel. Due to the non-return valves in the out port of the units, only the stronger one contributes fuel to the carburators.
My fuel line offers the option to connect a pression gauge (02). The fuel pressure of the single mechanical pump, at idle 450 rpm, is shown in (03), at 2000 rpm in (04).
The fuel pressure of the single electrical pump is shown in (05, and is independent of the rpm.
When both pumps are active, the dominant electrical pump defines the fuel pressure. So far, just for information. – SERGE –
Edited by sermey 2023-04-01 9:49 AM
(01 Glass Fuel Filter.jpg)
(02 Port for Pressure Gauge.jpg)
(03 Mechanical Fuel Pump 450rpm.jpg)
(04 Mechanical Fuel Pump 2000rpm.jpg)
(05 Electrical Fuel Pump.jpg)
01 Glass Fuel Filter.jpg (107KB - 49 downloads)
02 Port for Pressure Gauge.jpg (136KB - 51 downloads)
03 Mechanical Fuel Pump 450rpm.jpg (127KB - 55 downloads)
04 Mechanical Fuel Pump 2000rpm.jpg (135KB - 51 downloads)
05 Electrical Fuel Pump.jpg (133KB - 49 downloads)
Dual Front Door Catch System: Hitting the door to another car or wall – a big disaster due to the expensive replacement of the rare sheet metal.
This Dual Front Door Catch System, passenger and driver side, for 1959 Dodge and Plymouth (10), may fit as well for years 1956 (11), 1957 and 1958.
HighTech 3D engineered and simulated. Precision stainless steel parts, Laser cut to fit to minimum gap of 1mm. Smooth, floating roller-based operation, thus no additional door friction until snap (01). Dual trap position. First trap (02) aperture 65cm (03). Second trap (04) aperture 110cm (05). Fully opened (06) 150cm as original. Determined snap-in (07). Release force adjustable.
A unique compact set: 32 items, included stainless hex screws with matching tool, drilling template (08) and the mounting instructions. After drilled ready for mount.
An indispensable safety feature, for a valuable vehicle, avoiding damage when parking, and on slanting streets. A standard on all today’s vehicles. - SERGE -
Edited by sermey 2023-04-22 5:48 AM
(01 Top View.jpg)
(02 First Trap.jpg)
(03 Measured 64cm.jpg)
(04 Second Trap.jpg)
(05 Measured 110cm.jpg)
(06 Door fully opened 150cm.jpg)
(07 Front View CAD.jpg)
(08 Drilling Template A4.jpg)
(09 Assembled Trap Bar CAD.jpg)
(10 1959 Plymouth Door Fully Opened.jpg)
(12 56Dodge Dave FrontDoorShowingDoorStopInAction.jpg)
01 Top View.jpg (128KB - 50 downloads)
02 First Trap.jpg (133KB - 50 downloads)
03 Measured 64cm.jpg (112KB - 51 downloads)
04 Second Trap.jpg (122KB - 47 downloads)
05 Measured 110cm.jpg (110KB - 47 downloads)
06 Door fully opened 150cm.jpg (102KB - 47 downloads)
07 Front View CAD.jpg (68KB - 48 downloads)
08 Drilling Template A4.jpg (90KB - 46 downloads)
09 Assembled Trap Bar CAD.jpg (75KB - 49 downloads)
10 1959 Plymouth Door Fully Opened.jpg (118KB - 45 downloads)
11 56DodgeD500_4502_RightsideCourtesyLightPlunger.jpg (114KB - 50 downloads)
12 56Dodge Dave FrontDoorShowingDoorStopInAction.jpg (159KB - 48 downloads)
Compatibilty to other Mopars: I was asked about. Here to compare, a picture with transparent front at fully opened door, and the link:
Edited by sermey 2023-04-23 2:33 PM
(2023-04-23 Original Front Door Stop FWL.jpg)
2023-04-23 Original Front Door Stop FWL.jpg (89KB - 44 downloads)
Checking the Neutral Safety Switch: (01) It happens once, the starter motor didn’t engage in N position. I switched the push buttons to R, then to D, and back again to N. So the starter ran and then motor as well.
To know: This device is not a switch from a classic point of view. It consists of a movable bolt as contact element, guided by the isolation, and pressed out by an internal spring. It activates the relay to the starter.
Unmounted: Whatever the position of this contact, the resistance between the wire connection and the bolt (04) should always show 0 Ohm, as well when bolt point is pressed down (02). Measured 0.1 Ohm on point, 0.00 Ohm when fully pushed in (for test). As stated, this device is not a switch, but acts as a flexible conductor, or simply a contact device. Thus, following I will talk about contact, or about safety switch.
The contact is ON when the transmission lever (03) touches the point of the safety switch, and thus the connection turns grounded. This only happens when the gear is set to N position (04). For safety, the starter motor should only work in N position. So far so good and well known. -
I did some electrical measurements on this device. from wire connection to ground (04), the safety switch always mounted, and the cable connected. Measuring Ohms the battery is disconnected:
Result should be: (Instrument checked for 0.0 Ohm at short circuit)
Position ignition switch OFF and battery disconnected: (N) position -> 0 Ohm (R or D) position -> High Ohm
Position ignition switch ON and battery connected: (N) position -> 0 Volt (R or D) position -> Battery Voltage 12V
Position ignition switch OFF and battery disconnected: (N) position -> switched multiple: 1.7 – 6.9 Ohm (06), but never 0 as it should show. Sometimes even up to 60 Ohm (!).
I unlocked the adjustment wheel (07) by rotating out to get the gearshift control cable somewhat movable. Now pushed it in < - > out to find minimum Ohm reading, fixed it at this optimized position.
Result Now at optimized position:
Position ignition switch OFF and battery disconnected: (N) position -> up to max 1.3 Ohm (08)
Position ignition switch ON and battery connected: (N) position -> starter motor will always work
This proceeding may be considered as another, simple operational check of the Neutral Safety Switch, without unmount. A way for electrically fine position the control cable to the peak of the contact lever (03).
- SERGE -
N.B If the safety switch shows in any position 0 Ohm, resp. 0 Volt, then there is a short-circuit, and no start protection. If there is always High Ohm, resp. 12 Volt, then there is no contact at all. The car cannot be started. May be too low pressure from the bolt to the contact lever, the internal spring may be weakened or even broken. In both cases the switch must be replaced (09). By switching the gear selector (10) before starting several times from R to N and the other way back, the contact may be cleaned.
Some basics and pictures presented earlier by courtesy of Phil Courant (Phil_the_frenchie).
Edited by sermey 2023-04-29 12:16 PM
(01 Neutral Safety Switch.jpg)
(02 Contact Pressed in.jpg)
(03 View on Transmission Contact Lever.jpg)
(04 Electric Test Connection.jpg)
(06 Reading 1.7 - 6.9 Ohm.jpg)
(07 Turning out the adjustment washer.jpg)
(08 Reading max Ohm 1.3 Ohm.jpg)
(10 Push Button Unit.jpg)
01 Neutral Safety Switch.jpg (81KB - 46 downloads)
02 Contact Pressed in.jpg (62KB - 42 downloads)
03 View on Transmission Contact Lever.jpg (154KB - 45 downloads)
04 Electric Test Connection.jpg (111KB - 43 downloads)
05 PhilCourantsSafetyLeverContactingSafetySwitchInNeutral.jpg (129KB - 44 downloads)
06 Reading 1.7 - 6.9 Ohm.jpg (123KB - 45 downloads)
07 Turning out the adjustment washer.jpg (69KB - 49 downloads)
08 Reading max Ohm 1.3 Ohm.jpg (136KB - 45 downloads)
09 PhilCourantsNeutralSafetySwitch_1704283.jpg (138KB - 46 downloads)
10 Push Button Unit.jpg (115KB - 40 downloads)
Color of a Convertible Top: There are two ways for select the color of a convertible top: Original color or Custom color.
When I got my 1959 Dodge Custom Royal Lancer Convertible, it had a white top, greyed-out similar as shown in (01), and partly broken at the edges. The new included white top I gave to a friend as gift, for I decided to switch to black.
Can say, never a white top on a white car, for the color will barely match, fade out in time, and show any dirt. Except to a white paint, a white top will fit to any other color. On the other side, any other top color may fit to a white car. This my personal view from an esthetical and practical point.
The black top on my convertible looks always as new, now even many years later (02)(03)(04). - SERGE -
Edited by sermey 2023-05-29 2:51 AM
(01 Convertible Top White Greyed.jpg)
(02 Convertible Top Black.jpg)
(03 Convertible Top Black.jpg)
(04 Convertible Top Black.jpg)
01 Convertible Top White Greyed.jpg (110KB - 34 downloads)
02 Convertible Top Black.jpg (142KB - 38 downloads)
03 Convertible Top Black.jpg (141KB - 39 downloads)
04 Convertible Top Black.jpg (105KB - 41 downloads)
Swivel Seat Back Snap System: The back of my swivel seats never kept in back position. When braking strongly, without passenger sitting, the seat turned to front.
I was told that there is a retarder spring in the hinge, and found it in the 59 Dodge Parts List as 23-45-55 Swivel Seat Back Retarder (00).
Ahead years a FWL-friend sent me pictures with the exact dimensions (01 – 05), and could model in 3D-CAD (06). It had just to be reproduced from a bent spring steel profile . . . but I never did. Attached the 3D CAD-File (07).
Now I restarted to solve this problem and came to a simple snap system, even Master Exner would have liked. As learned by experience, most Mopar people is not in the position to pay for expensive precision laser-cut spring brackets, as it should be needed.
Hence I will friendly show here next, how to do-it-yourself, from scratch. You will start without knowing how it works, illustrated by 3D-CAD in RealView, step by step. - SERGE -
Edited by sermey 2023-06-08 3:54 PM
(00 1959 Dodge Parts List Spring 23-45-55 .jpg)
(01 Dimensions Swivel Seat Back Retarder Spring.jpg)
(02 Dimensions Swivel Seat Back Retarder Spring.jpg)
(03 Dimensions Swivel Seat Back Retarder Spring.jpg)
(04 Dimensions Swivel Seat Back Retarder Spring.jpg)
(05 Swivel Seat Back Retarder Spring.jpg)
(06 CAD Swivel Seat Back Retarder Spring.jpg)
00 1959 Dodge Parts List Spring 23-45-55 .jpg (181KB - 36 downloads)
01 Dimensions Swivel Seat Back Retarder Spring.jpg (116KB - 39 downloads)
02 Dimensions Swivel Seat Back Retarder Spring.jpg (118KB - 37 downloads)
03 Dimensions Swivel Seat Back Retarder Spring.jpg (99KB - 37 downloads)
04 Dimensions Swivel Seat Back Retarder Spring.jpg (92KB - 36 downloads)
05 Swivel Seat Back Retarder Spring.jpg (50KB - 39 downloads)
06 CAD Swivel Seat Back Retarder Spring.jpg (68KB - 36 downloads)
07 CAD Swivel Seat Back Retarder Spring.STEP (73KB - 40 downloads)
Location: D-70199 Heslach
|Off topic,- Sermey, are you going to lakeside-meet on the coming weekend?|
sermey - 2023-06-14 5:28 PM
I think so, a sunny Sunday. Hope to meet you there, Tom.
Edited by sermey 2023-06-15 12:51 AM
(2023-06-18 Lakeside Meeting CH.jpg)
2023-06-18 Lakeside Meeting CH.jpg (173KB - 37 downloads)
Location: D-70199 Heslach
sermey - 2023-06-14 4:28 PM
I think so, on sunny Sunday. Hope to meet you there, Tom.
Look for a 69 Barracuda w/ Mod Top
sermey - 2023-06-08 7:19 PM
Swivel Seatback Retarder Spring: To complete the views of this spring here the pictures as I got from our friend Stefan, taken from his 1959 Plymouth (01 – 05). I tried to assemble in CAD, just by pictures.
Seatback in Rear/Front Position (06), Seatback with Spring in Rear and Front Position (07), and an Exploded View (08). Not having the spring, I don’t know if this is correct, and if 1959 Plymouth and 1959 Dodge are identical.
Could not add the STEP-File (800kB) for correct if needed. - SERGE -
Edited by sermey 2023-06-23 6:31 AM
(01 Mountposition side view.jpg)
(02 Mountposition top view.jpg)
(03 Rear view.jpg)
(04 Spring position.jpg)
(05 Spring mounted.jpg)
(06 CAD Assembled Dual Position.jpg)
(07 CAD Rear - Front View Transparent.jpg)
(08 CAD Exploded View.jpg)
01 Mountposition side view.jpg (118KB - 42 downloads)
02 Mountposition top view.jpg (160KB - 37 downloads)
03 Rear view.jpg (127KB - 40 downloads)
04 Spring position.jpg (126KB - 35 downloads)
05 Spring mounted.jpg (111KB - 39 downloads)
06 CAD Assembled Dual Position.jpg (103KB - 43 downloads)
07 CAD Rear - Front View Transparent.jpg (93KB - 40 downloads)
08 CAD Exploded View.jpg (76KB - 40 downloads)
sermey - 2023-06-08 7:19 PM
Retarder Spring Swivel Seatback (Correction): I just noticed that the retarder spring is placed on the wrong side. Forced from down-up it will initially move and touch the left side (09). Correct?
“errare humanum est” - SERGE -
Edited by sermey 2023-06-28 3:51 AM
(09 CAD Retarder Spring corrected Position.jpg)
09 CAD Retarder Spring corrected Position.jpg (104KB - 35 downloads)
Swivel Seat Back Snap System (1): Now you will see how to do yourself the snap system, illustrated by CAD, step by step. For better distinguish, shown as well in line view. The seatback is represented by its arm end, right side hinge. The left side proceed similar.
All illustrations are mostly self-explanatory. In the last part I will show the real application on my car.
Proceeding Part 1
1. Take a stainless spring steel sheet metal, preferably type 1.4310 C1300, thickness 0.5 – 1 mm. Cut it to length 110 x 12mm, and bend it around the O-Profile (01), so as to fit around the cross-section: Di 16.4mm, Ri 5mm. I call it the spring bracket.
For easier access the seatback can be removed.
2. The spring bracket is pushed over the O-Profile, aligned to the upper border, and fixed by a clamp. The seatback is mounted, kept in fully Rear Position (Pos. 1, grey), 0 deg:
Now pre-drill 3mm, perpendicular over the screw axis, in the center and 6mm from border of the spring bracket. To get all straight in-line, drill through all-in-one step (02).
The spring steel require a hard driller. Then the mounted spring (fix it!) can be used as a template for the O-profile (03). When done remove the spring bracket. From now, the pre-drilled O-profile 3.0mm, will be used as drilling template (04).
3. Set the seatback in fully Rear position, pre-drill again 3mm through the seatback arm (Position 1). Same in Front Position (Pos. 3, green), 65deg (05). And again in Center Position (Pos. 2, blue), 32.5deg (06). Or may choose your preferred intermediate position. For multiple snap positions, multiple holes can be drilled. Will always drill only through the seatback arm.
On removed seatback, drill-up all from 3mm to 6.0mm, and add on both sides a chamfer 1.0mm-45deg, or d = 8.0mm using a countersink (07). These holes will define the 3 snap positions (08).
4. The spring bracket removed, drill-up from 3mm to 6.0mm, cut and round the end as shown (09). Now the spring bracket, the key component of the system, is done and ready(10). It should exactly fit when fully pushed-in on the O-profile.
STEP-files are attached for the bent (11) and the flat (12) spring bracket.
Now you may already find out how this system works. – SERGE –
Edited by sermey 2023-07-08 5:35 AM
(01 Create Stainless Spring Bar 100 x 12 x 0.5mm and bend.jpg)
(02 Seatback in Rear Position - predrill 3mm.jpg)
(03 Spring Bracket - bent and pre-drilled 3mm.jpg)
(04 O-Profile as template pre-drilled 3mm.jpg)
(05 Seatback in Front Position - PreDrill again 3mm.jpg)
(06 Seatback in Center Position - PreDrill again 3mm.jpg)
(07 3 Snap Holes drilled-up 3mm to 6mm .jpg)
(08 Applied Chamfer 0.5mm 45deg to snap holes.jpg)
(09 Spring Bracket drilled-up to 6mm - End rounded.jpg)
(10 Flat Bracket L = 101.87 W = 12mm d = 77.87mm D = 6.0mm.jpg)
01 Create Stainless Spring Bar 100 x 12 x 0.5mm and bend.jpg (90KB - 32 downloads)
02 Seatback in Rear Position - predrill 3mm.jpg (79KB - 31 downloads)
03 Spring Bracket - bent and pre-drilled 3mm.jpg (70KB - 30 downloads)
04 O-Profile as template pre-drilled 3mm.jpg (72KB - 30 downloads)
05 Seatback in Front Position - PreDrill again 3mm.jpg (84KB - 30 downloads)
06 Seatback in Center Position - PreDrill again 3mm.jpg (83KB - 34 downloads)
07 3 Snap Holes drilled-up 3mm to 6mm .jpg (75KB - 32 downloads)
08 Applied Chamfer 0.5mm 45deg to snap holes.jpg (103KB - 31 downloads)
09 Spring Bracket drilled-up to 6mm - End rounded.jpg (75KB - 32 downloads)
10 Flat Bracket L = 101.87 W = 12mm d = 77.87mm D = 6.0mm.jpg (58KB - 30 downloads)
11 Spring Bracket.STEP (98KB - 38 downloads)
12 Spring Bracket Flat.STEP (40KB - 33 downloads)
Swivel Seat Back Snap System (2): As the spring brackets are disposable, the o-profile (not the seat arm!) can be drilled up to 9.05mm, fitting the steel ball D = 9.0mm (13). The overall exploded view shows all needed parts and the function of the snap system (14).
The two steel balls are inserted, then the spring bracket pushed over the o-profile to its final position (15), without the need of any tools and self positioning. The preloaded bracket is slightly bent in operation mode. In the cross section view the contact points can easy be verified (16)(17).
Now the assembled snap system looks very discreet, the practical function must be approved, especially the snap force. This should be optimized, mostly with the diameter of the holes in the seat arm, and somewhat with a harder the spring bracket.
In (3) I will present the applied realization on my 1959 Dodge Custom Royal Lancer Convertible.
After that a much simpler Seat Back Lock System, applicable for mostly all 2-Door Mopars 1957 - 1959 (?). - SERGE -
Edited by sermey 2023-08-06 7:13 AM
(13 Drill 9.05mm only through O-Profile.jpg)
(14 Exploded View.jpg)
(15 Spring Brackets Flat - Active - Preloaded.jpg)
(16 Cross Section Zoomed Bracket Active 1.2mm.jpg)
(17 Cross Section Zoomed Bracket Active 1.2mm.jpg)
(18 Assembled Snap System 3 Positions.jpg)
13 Drill 9.05mm only through O-Profile.jpg (100KB - 30 downloads)
14 Exploded View.jpg (148KB - 28 downloads)
15 Spring Brackets Flat - Active - Preloaded.jpg (109KB - 28 downloads)
16 Cross Section Zoomed Bracket Active 1.2mm.jpg (143KB - 33 downloads)
17 Cross Section Zoomed Bracket Active 1.2mm.jpg (158KB - 32 downloads)
18 Assembled Snap System 3 Positions.jpg (128KB - 29 downloads)
Swivel Seat Back Snap System (3), Application: As intended for “Do-it-Yourself”, most operations are best described with pictures. This especially for “non-mechanical” readers. Apart from drilling, the main job needs the spring bracket.
Organize some stainless spring sheet metal, d0.5 – 1.5mm (**) (01), and cut in stripes of 100 x 12mm (02). Bend, using the O-profile or another item as template (03). First tests (04). For easier process I found table clips in multipack, high flexible, 12mm x 0.6mm (05). Even very hard, could cut them with a scissor (06). Enlarge the existing radius to R5mm (07), and bend the other radius correspondingly (08) to fit the O-profile (09). Mark the drill position, just over the pivot (10), and drill D6mm on both sides (need HSS-CO Metal Drill and lubrication) (11).
Shorten both ends with the metal scissor (12) to get the final length (13). After that, round them by machine grinding (14). The final spring bracket now can be pushed on for mark the drilling center (15).
The seat back is set in the back – front- and mid position. Pre-drill first all with D3mm, trough all. Then remove the seat back, and drill up all holes in the arm from D3mm to D6mm (**), apply some chamfer (not shown). Still at removed back seat, drill up the O-profile to D9.05mm (16), as the steel balls have D9.00mm.
Now, at mounted back seat, the steel balls can be loaded from both sides (17), then the spring bracket pushed over. It will keep in place when all is done accurately.
The Swivel Back Seat Snap System is ready to operate (18).
Result: I started first on the passenger side, rear and front position. The system as presented shows a too week snapping, as expected due to the thin spring d0.6mm, and too wide chamfer on the arm.. Means, for best snap the tagged values (**) need to be optimized.
Conclusion: In view of a simpler and more useful Back Seat Lock solution, being presented soon, I don’t recommend to work on this snap system. Anyway, both work simultaneously, independent from each to other.
For you this project shows the applied interaction between CAD and Mechanics. For me, it was another challenging game! - SERGE -
(01 Selected Stainless Sheet Metal.jpg)
(02 Cut Metal Stripes.jpg)
(03 Manual Bent with Profile as Template.JPG)
(04 First Tests.jpg)
(05 Table Clips in Multipack.jpg)
(06 Pre-Cut the Table Clips.jpg)
(07 Enlarge the Radius to 5mm.jpg)
(08 Bent Stripes.jpg)
(09 Check the Roundings.jpg)
(10 Mark the Drill Position.jpg)
(11 Drilled 6mm.jpg)
(12 Cut with Metal Scissor.jpg)
(13 Cut with Metal Scissor.jpg)
(14 Drilled Brackets rounded.jpg)
(15 Drilled Bracket mounted.jpg)
(16 O-Profile drilled up 9.05mm for Ball.jpg)
(17 Assembled Snap System.jpg)
(18 Final System Overview.jpg)
01 Selected Stainless Sheet Metal.jpg (118KB - 28 downloads)
02 Cut Metal Stripes.jpg (126KB - 27 downloads)
03 Manual Bent with Profile as Template.JPG (108KB - 26 downloads)
04 First Tests.jpg (93KB - 28 downloads)
05 Table Clips in Multipack.jpg (91KB - 24 downloads)
06 Pre-Cut the Table Clips.jpg (109KB - 27 downloads)
07 Enlarge the Radius to 5mm.jpg (127KB - 29 downloads)
08 Bent Stripes.jpg (107KB - 28 downloads)
09 Check the Roundings.jpg (149KB - 29 downloads)
10 Mark the Drill Position.jpg (123KB - 27 downloads)
11 Drilled 6mm.jpg (84KB - 29 downloads)
12 Cut with Metal Scissor.jpg (92KB - 30 downloads)
13 Cut with Metal Scissor.jpg (103KB - 25 downloads)
14 Drilled Brackets rounded.jpg (97KB - 27 downloads)
15 Drilled Bracket mounted.jpg (139KB - 25 downloads)
16 O-Profile drilled up 9.05mm for Ball.jpg (154KB - 26 downloads)
17 Assembled Snap System.jpg (165KB - 30 downloads)
18 Final System Overview.jpg (147KB - 28 downloads)
|Amazing stuff as always Serge. I think you are the FWL " quantum physician "|
22mafeja - 2023-08-13 8:20 AM Amazing stuff as always Serge. I think you are the FWL " quantum physician "
What a compliment, Ralf. In respect to all here doing a big job on their Mopar, I try to compete somewhat on my own way.
Thanks. - SERGE -
Edited by sermey 2023-08-14 1:53 AM
Seat Back Lock: It was obvious to come across a lock solution -> ingenious as trivial. The few commercially available components prove it (01):
1. Flange head screw with inside hexagon, stainless steel, M5 x 30mm
2. Round Spacer Nut, stainless steel, M5 x 10 x 10mm
3. Conical Compression Spring, stainless steel, D12 x d6 x H12mm
4. Round Knob with threaded sleeve, glossy black, M5 x D21 x d12 x H21mm
Components assembled $5 (02), set per vehicle $10 (03). The biggest effort is to find some vendors, then to the low cost adds the shipment, and for less than 20 pieces each you are mostly supplied.
The round knob I cut from H21 to H15mm to appear more discreet (04). So let’s start, in less than 2 hours you get it:
Drill D5mm through all, at fully rear seat back position, dimensions H17 - D13mm from border (05). It doesn’t influence the prior snap system (05a). Use a 90deg drill-adapter. Drill-up to D10mm from the other side, only the half O-profile and through the seat arm (06).
It can as well be drilled at removed seat back. Then when re-assembled, do re-drill in one with a precision milling drill, so as both D10mm holes are exact in-line. To protect the upholstery apply a strong plastic sheet (07). The brittle HSS-Kobalt drill has broken, thus now shortened. Use reduced rpm and lubricate.
For free moving the seat back, the arm needs a gap. Mark the center-line with a waterproof felt-pen. Held in the 5mm hole, and move the seat back front to rear (08). Offset the curved line to 6mm width, and cut-out using a jigsaw (09) (09a).
Can see where rasped 4.5mm deep for increasing the seat back angle, as shown in:
Now assemble all: Insert the screw with the spacer nut mounted. Put on the conical compression spring. The direction is indifferent. Turn-on the knob to a remaining play of 5.5mm, to be fixed with LOCTITE. The feature is ready to operate:
- Push-in the knob for unlock (11): the seat back is free to move.
- Move the seat back to front, till the lock unit snaps automatic in: It will stay locked at 60deg (10).
- To unlock push-in again the knob (11): The seat back is free to turn back, to the rear position. It will snap in automatic and keep locked (12).
There are many other M5 knobs available for make it more discreet, as balls in chrome 10mm, with flat head, or in miniature. I feel the presented version is handy, ergonomic and best for my car (13).
Another exclusive feature for your Dodge (and other Mopars 1957 – 1959): Easy to build - simple to operate - comfortable for access to rear - steady at strong braking - strong and secure. A joy to do it and then use.
Once more -> ingenious as trivial. - SERGE -
N.B. Next thread will show the corresponding CAD pictures only.
Edited by sermey 2023-08-16 11:18 PM
(02 Components Assembled.jpg)
(03 Set per Vehicle.jpg)
(04 Shortened Knob.jpg)
(05 Dimensions H13-V17mm.jpg)
(05a Drill 5mm through all.jpg)
(06 Drill Adapter 90deg for 10mm.jpg)
(07 Protected Upholstery.jpg)
(08 Mark Center Gap.jpg)
(09 Cut Gap.jpg)
(09a Other Gap 6mm.jpg)
(10 Front Position Locked.jpg)
(11 Push-in for Unlock.jpg)
(12 Rear Position Locked.jpg)
(13 Front Position Locked.jpg)
01 Components.JPG (125KB - 30 downloads)
02 Components Assembled.jpg (116KB - 23 downloads)
03 Set per Vehicle.jpg (104KB - 25 downloads)
04 Shortened Knob.jpg (95KB - 26 downloads)
05 Dimensions H13-V17mm.jpg (88KB - 25 downloads)
05a Drill 5mm through all.jpg (188KB - 25 downloads)
06 Drill Adapter 90deg for 10mm.jpg (116KB - 29 downloads)
07 Protected Upholstery.jpg (192KB - 23 downloads)
08 Mark Center Gap.jpg (218KB - 25 downloads)
09 Cut Gap.jpg (114KB - 26 downloads)
09a Other Gap 6mm.jpg (177KB - 24 downloads)
10 Front Position Locked.jpg (207KB - 74 downloads)
11 Push-in for Unlock.jpg (182KB - 24 downloads)
12 Rear Position Locked.jpg (175KB - 22 downloads)
13 Front Position Locked.jpg (197KB - 26 downloads)
Board Moderator & Exner Expert 10K+
Location: Southern Sweden - Sturkö island
|Very nice solution Serge, that will solve the seatback problems! |
sermey - 2023-08-16 7:13 PM Seat Back Lock
In Addition: Only CAD pictures
Some pictures practical same, but for those less familiar thinking in 3D. - SERGE -
(01 Exploded View CAD.jpg)
(02 Exploded View CAD.jpg)
(03 Spring Comparison CAD.jpg)
(04 Spring Comparison CAD.jpg)
(05 Reversed Spring CAD.jpg)
(06 Unlock - Lock CAD.jpg)
(07 Lock - Unlock CAD.jpg)
(08 Front Unlock - Lock CAD.jpg)
(09 Lock - Unlock CAD.jpg)
(10 Lock - Unlock CAD.jpg)
(11 Free - Unlocked CAD.jpg)
(12 Rear View Locked CAD.jpg)
(13 Front Position 60deg CAD.jpg)
(14 Disassembled CAD.jpg)
(15 Disassembled - other view CAD.jpg)
01 Exploded View CAD.jpg (96KB - 24 downloads)
02 Exploded View CAD.jpg (66KB - 25 downloads)
03 Spring Comparison CAD.jpg (94KB - 27 downloads)
04 Spring Comparison CAD.jpg (66KB - 21 downloads)
05 Reversed Spring CAD.jpg (80KB - 24 downloads)
06 Unlock - Lock CAD.jpg (72KB - 25 downloads)
07 Lock - Unlock CAD.jpg (91KB - 26 downloads)
08 Front Unlock - Lock CAD.jpg (88KB - 25 downloads)
09 Lock - Unlock CAD.jpg (136KB - 22 downloads)
10 Lock - Unlock CAD.jpg (101KB - 24 downloads)
11 Free - Unlocked CAD.jpg (77KB - 23 downloads)
12 Rear View Locked CAD.jpg (112KB - 24 downloads)
13 Front Position 60deg CAD.jpg (64KB - 26 downloads)
14 Disassembled CAD.jpg (57KB - 22 downloads)
15 Disassembled - other view CAD.jpg (74KB - 26 downloads)
sermey - 2023-08-22 2:57 PM
sermey - 2023-08-16 7:13 PM Seat Back Lock
In Addition: Another variation
For those who like it less visible and even cheaper, the black knob can be replaced by another screw (16). Important that the flange distance is kept to 23mm (17).
Screw1: M5 x 5mm Screw 2: M5 x 18mm
Now the unit can only be pushed-in, this for unlock the seat back. In the snap position the spring will shift it back and lock again. The seat back should be “unloaded” and in the snap-in position (18). – SERGE -
(16 No Black Knob CAD.jpg)
(17 Dimensions - Comparison CAD.jpg)
(18 Final View CAD.jpg)
16 No Black Knob CAD.jpg (102KB - 25 downloads)
17 Dimensions - Comparison CAD.jpg (90KB - 26 downloads)
18 Final View CAD.jpg (76KB - 22 downloads)
Must precise: All previous swivel seat back considerations shown here are related to a 1959 Dodge Convertible.
Edited by sermey 2023-08-27 4:55 PM
Conical Compression Spring: I was kindly asked to publish the supplier of the conical compression springs. Here it is (01) (02):
Then I added the 3D-CAD Models as PDF-Files for those interested in 3D Technology. The normal spring unloaded (04), the OP spring loaded (05) and the flat spring (06).Other file formats are too big to post here. When opened with Adobe Acrobat, accept to trust in Options (Message: 3D content has been disabled. Enable this feature if you trust this document). The models can be 3D handled (rotated, zoomed).
Good luck when assembling. - SERGE -
Edited by sermey 2023-09-01 8:58 PM
(01 Normal Skewer Spring.jpg)
(02 Dimensions Skewer Spring.jpg)
(03 Normal - OP - Flat Spring CAD.jpg)
01 Normal Skewer Spring.jpg (129KB - 25 downloads)
02 Dimensions Skewer Spring.jpg (58KB - 22 downloads)
03 Normal - OP - Flat Spring CAD.jpg (94KB - 22 downloads)
04 Normal Skewer Spring 3D-CAD.PDF (93KB - 24 downloads)
05 OP Skewer Spring 3D-CAD.pdf (118KB - 25 downloads)
06 Flat Skewer Spring 3D-CAD.PDF (114KB - 24 downloads)
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