Completed Projects

Completed Automotive Car Restoration

This page shows some of The Metal Surgeon’s completed automotive car restoration.  Some of our projects do not require us to do paint and final assembly, since some work is we do is for for local restoration shops.  In those cases we complete at minimum the metal work, then they assemble in house and present to the customer.  Also, some of our customers prefer to do the final assembly of the car in their own garages.

We do a wide variety of metal work from your straight down the line nut and bolt restoration, to a full custom ‘one of a kind,‘ to concept engineering/fabrication projects like the Mercedes Unimog.

The nice thing about our new 8,000 sqft facility is we can work on more projects with our well qualified 5-man team.  Be sure to also check out our current projects page.

Before Car Restoration – Porsche 914 to 914-6 GT conversion/car restoration

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

After Car Restoration – 914-GT in paint, ready for for assembly

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

See full details on this 914 build here.


After Car Restoration- Porsche 356 Pre-A in Paint

See full details on this 356 Pre-A build here.


Before Car Restoration- Mercedes Unimog Fabrication

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon
Mercedes Unimog concept build for a landmine investigation company.  This is how the truck was delivered to us.

After Car Restoration – Mercedes Unimog Fabrication

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon
Hand crafted floors.
Truck & Car Restoration Projects Completed In USA at The Metal SurgeonEntire back end of the Unimog was designed and fabricated by The Metal Surgeon.


Before – 1938 Chevrolet Pepsi Truck restoration

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Original, but worn interior.

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Check out the center hinged hood and side panel mechanism. This will be replaced with a full custom one piece hood.

After – 1938 Chevrolet Pepsi Truck

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Custom made aluminium one piece forward moving hood.

See full details on this Custom Chevy Truck build here.


American Austin – Metal Work completed

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

American Austin – in Paint

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon
Truck & Car Restoration Projects Completed In USA at The Metal Surgeon


Before – rebuild of Mercedes front end

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon1957 Mercedes 300SL complete front end rebuild from scratch. Work done for a local restoration company.

After – Metal work and Paint Completed on the 300SL

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon
Truck & Car Restoration Projects Completed In USA at The Metal SurgeonIn final paint (this step not completed by us).

Custom hood scoop

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Created for a Sunbeam Tiger.


 SWB Ferrari bumper made from scratch

Truck & Car Restoration Projects Completed In USA at The Metal SurgeonShort wheel base (SWB) Ferrari rear bumper made from scratch for a Ferrari restoration company in Orange County, CA.
Truck & Car Restoration Projects Completed In USA at The Metal SurgeonSide view of the wrap around bumper.


 Before – 1968 VW Bus Bay Window

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon
This is how the 1968 Bay Window came to the work shop; the front end was crushed  from an impact to the spare wheel;  the driver’s side floor was rotted out; the original trim was damaged; there were random holes drilled for antennas and mirrors; plus there were several isolated rusted areas.

After – 68 VW Bus Restoration

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

1968 VW completed with a fresh paint job. Car restoration process:  Jalousie windows were removed and replaced with original window/vent configuration from the factory.  New weather stripping all round.  Powder coated wheels and new German hubcaps with hand painted VW logos.  Restored original bumpers to factory cloud white.  Custom handmade fresh air intake vent housing.


Before – Triumph TR3A Car Restoration

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon
A 1959 Triumph TR3A that we completed metal work and paint for Duke’s Garage.



Before – Porsche 356A Rear End Rebuild

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

1959 Porsche 356A rear end rebuild for a local restoration company (Classic Investments).

After – Porsche 356A Rebuild

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Rear of Porsche was completely removed and repaired due to an accident that left it misshapen.


 Before – Porsche 356 Complete Metal Work

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

1963 Porsche 356C Cabriolet metal work and paint for a local restoration company, Classic Investments. Body had suffered some poor repair attempts in the past.

 After – Porsche 356 Complete Car Restoration

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Porsche 356C in paint, (final assembly done at Classic Investments).


 Before – Porsche 911 Inner Fender Panel

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Early Porsche 911 inner fender panels for a local car restoration company (Vintage Car Works).

 After – Porsche 911 Inner Fender Panels Reproduced

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Final fender panels, these are not mass reproduced and therefore the originals had to be repaired or reproduced.

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon

Early Porsche 911 with new inner fender panels fitted.


Before and After Photos of a Car Filter Restoration

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon


Custom Grille Shell and Insert Panel for 32 Ford

Truck & Car Restoration Projects Completed In USA at The Metal SurgeonA custom 1932 Ford radiator shell made from aluminum.

Truck & Car Restoration Projects Completed In USA at The Metal SurgeonA Bonneville-style grille insert to fit any shell. This shell was narrowed 1-inch from the original. Only one in the world!


 Custom Dashboards for Early Fords

Truck & Car Restoration Projects Completed In USA at The Metal Surgeon1929 Ford roadster custom aluminum dashboard to house an Auburn instrument panel.

Truck & Car Restoration Projects Completed In USA at The Metal SurgeonA 1932 Ford roadster custom aluminum dashboard to house an Auburn instrument panel.

This site is protected by Comment SPAM Wiper.