This is part five of the automotive restoration series on this 1960 Ferrari PF Cab. For Part One, which describes the creation of a ‘measuring box’ to check the car body symmetry, click here. For Part Two, which describes the creation of a new rear light housing, click here.  For Part Three, which covers patterning up the rocker panels, click here.  For Part Four, which looks at how the original rocker panels were dismantled, click here.

Now we are at the stage where we handcraft new panels to replace the originals as part of the overall restoration of this 1960 Ferrari 250 GT.  After cleaning out the old decayed metal, making the lower bracket jig, and media blasting, we can begin putting together new panels we’ve made onto the car to ensure a good and correct fit.  As we build on the car, this allows us to correct and finesse the panels as we go along.  The lower ‘A’ post panels have to be put together keeping in mind clearance issues on the lower door bracket and outer rocker sheet metal.  The door bracket jig comes into play with helping us align not only the bracket, but the sheet metal behind.

Take a look at the photos below to see the process and progress.  The following stage will show the making and fitting of the rocker sheet metal.

 

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The two outer sections sandwiching the internal structural brackets held together with cleco's

 

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End view showing structure build up

 

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The sill is now added and clecoed into place. You can see the section where the 'A' post takes position as the sill steps around forming the stalk of the letter 'l'.

 

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The body of the new rocker now offered up to the Ferrari 250 GT for fitment.

 

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See where the sill takes on the shape of the 'A' post. The lower 'A' post has some replacement sheet metal that sits directly behind the lower bracket.

 

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Showing the fabrication and fitment of the lower 'A' post panel

 

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The full picture showing the rocker body, sill and lower 'A' post reconstruction. All panels fitted and ready for the next stage.

 

This is part five of the automotive restoration series on this 1960 Ferrari PF Cab. For Part One, which describes the creation of a ‘measuring box’ to check the car body symmetry, click here. For Part Two, which describes the creation of a new rear light housing, click here.  For Part Three, which covers patterning up the rocker panels, click here.  For Part Four, which looks at how the original rocker panels were dismantled, click here.

For more information on the The Metal Surgeon, see our services provided.

2 Responses

  1. alvin

    Just want to thank you …. for posting all these pics. After working 50 years on cars, bikes, boatengines and so on… I finally 3 months ago…started to weld/rust/cut/fabricate panels for my DeTomaso Pantera. I could not pay the guys who did not have the time and effort anyway… 🙂

    I use your way of making things – it shure takes a lot of time for me… and my level of work is sure way lower… BUT I can see what to do….. and I can also se, that the guys who made my Pantera in 1971 – could have learned a really lot from your skills/level of handcraft 🙂

    You make impressive work – to say the least…

    Greetings…

    alvin sorensen,

    Denmark.

    Reply

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