| We will make a new convertible top guide to demonstrate the procedure for making a new striker plate, stop or guide. |
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1. Here is the guide we want to reproduce. The material becomes brittle and over the years, causing it to crack and chip. |
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2. We are using a very durable plastic with natural lubricating properties and you can buy it at most plastic supply houses. It comes in black or milky white colors. |
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3. We start with a piece slightly larger then the original.
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4. Here we use the original as a template to mark the outside edges.
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5. Then we cut it out on a band saw, leaving an 1/8th inch margin for clamping.
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6. Here is what we have so far.
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7. The new material is slightly thicker than the original but that will not be a problem.
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8. Next we install the new piece in a three-way vise with a block of wood underneath for support. We will use a simple carbide burr in the drill press.
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9. Then we gradually create the desired shape by moving the vise.
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10. Here you can see what happens (the chip) if you move too fast.
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11. So we make nice, slow and steady passes.
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12. Now you can see that one side is cut to the right depth.
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13. And here we have cut down both sides. We will remove the wings at the ends with a belt sander before continuing.
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14. In this picture you can see that we used a piece of tape to create a template for the holes.
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15. Then we transferred the outside edges of the original piece to our new piece.
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16. Next we carefully handle the tape without using our hands to prevent a loss of stickem.
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17. And place it on the new piece so we can drill the holes in the correct location.
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18. Now we can use a hole to screw the piece onto a block of wood for the final steps. We are using a straight edge here to accurately measure for final tweaking.
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19. Here we are picking out a beveled bit to apply a slope to the guide.
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20. Now back to the drill press to cut the slope. This is also a good time to go back to the straight bit and trim the perimeter to the actual size.
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21. Finally, we alternate the hold-down screw so we can carefully countersink the holes.
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22. And then a quick pace on the belt sander to remove the burrs.
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23. Here you can see how well the new guides matches the original ones.
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24. And here you can see how they will look on the application.
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Jeff Lilly Restorations
11125 F.M.1560 N
San Antonio, Texas
210-695-5151 - www.jefflilly.com
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