Assembly line shortcuts

[Mike E.]

I spent one summer on an automotive-related assembly line, and quickly learned that you figured out every shortcut you could. Corvette assembly was no different. I recently sent a picture of these 68-72 wiper door retainers to Gary Bosselman and asked why they have the "staked" area on top. His reply was that they looked like they had been hit with a chisel and hammer. So we ruminated on that, and came up with this: The easiest way to align the wiper door assembly was to set all three mounts (4 nuts and studs, 2 screws total) to the highest point, and tighten the assembly there. Then, if either side or the middle needed further alignment, the line worker simply whacked at it with hammer and chisel, lowering it to the proper level. No doubt you did it that way on your early C3, so that it wasn't over-restored, right?

wiper door brackets and retainers (2).jpgwiper door brackets and retainers (1).jpgwiper door brackets and retainers (4).jpg

[Duke W.]

Re: Assembly line shortcuts

During my short tenure as a Pontiac production engineer in 1968 before heading off to grad school, I was at the Van Nuys plant (Camaros and Firebirds) for three weeks for changeover and the '69 pilot line build.

F-bodies were "half frame" cars. The body from cowl to trunk arrived from the Fisher Body side of the plant and was mated to a front subframe that contained the engine, front suspension, and steering. Once mated to the body and after some additional parts were added like brake pipes and wiring harnesses the front end sheet metal was installed - front fenders and hood (and finally the front bumper-grille assembly).

Once the fenders were installed, the hood was bolted on. Then one guy operated the hood while two other guys, one on each side pried it laterally as required with what were big hard rubber crow bars between the fender gutter and hood edge to get it to close properly with equal gaps on each side. As I watched this I thought of all the time I spent polishing the hood gutter and edges of the hood on my SWC.

Duke

[Mark E.]

Re: Assembly line shortcuts

This reminds me of a thread I saw here years ago describing how the top of mid-year coupe doors were bent to align with the roof. Looked a bit scary.

[Bill M.]

Re: Assembly line shortcuts

If it don't fit get a bigger hammer

[John D.]

Re: Assembly line shortcuts

Spent over 20 years in GM assembly plants and the fit and function line workers were some of the most experienced and skilled workers in the plant. Shortcuts to get things to work were often needed at line rates of up to 60 an hour for high volume models. I remember one old timer who told me he bought his first house with the OT from fixing the 6 way rear gates on the 70's era Chevy station wagons.

[Steven B.]

Re: Assembly line shortcuts

I'm a generation later than many on here, I started as a manufacturing engineer in the auto industry in the early 80's. I left the industry during Covid after almost 40 years. The evolution over that time has been interesting to watch and reflect back on. We progressed from 100% reworking a lot of parts to statistically capable processes producing parts that fit within tolerance most of the time with no rework needed. There are still a few hammers stashed here and there but things have changed in that respect. It's been an interesting journey.