Tag Archives: antique cars

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1932 Ford sedan “Lakester” roof chop: Part 2

This post covers the second part of a project in house for a customer based in Australia.  A 1932 Ford sedan in original paint, that is going to be turned into a Bonneville Lakester style build.

The second part of this series covers the remaining major areas of the custom build, which includes the rear window modification and roof insert panel.

Rear window custom modification

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Roof insert panel

classic restoration, sheet metal fabrication, custom metal worker, metal work denver, antique cars, automotive repair, automotive restoration, car body repair, classic cars, car restoration, metal working, restoration, vintage cars, ford Roof insert operation begins. Objective is to remove fully the wooden structure. The wood structure will be put back in once the roof insert panel is complete.

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Final metal work!

The car was displayed at this years Creme de la Chrome in downtown Denver to show the quality of what lies beneath our painted restorations.  The metal work is an important foundation for any restoration and it’s important to chose your shop wisely to make sure they have the necessary skill set to perform the duties on your classic vehicle.

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Complete view of the finished metal work at the show to back up our motto “know what’s under your paint.”

classic restoration, sheet metal fabrication, custom metal worker, metal work denver, antique cars, automotive repair, automotive restoration, car body repair, classic cars, car restoration, metal working, restoration, vintage cars, ford A custom grille insert to complete the front end ‘mock up,’ to give an overall view of the concept.

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Overall view of the the rear on display at the Creme de la Chrome show in downtown Denver 2014.

For even more photos and details on the build, check out this forum:

http://www.jalopyjournal.com/forum/threads/32-sedan-lakester-roof-chop.934219/

 

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1932 Ford Sedan ‘Lakester’ Roof Chop: Part 1

This post covers a new project in house for a customer based in Australia.  A 1932 Ford sedan in original paint, that is going to be turned into a Bonneville Lakester style build .

We started with stripping the body down, followed by plastic media blasting.  This body is super nice and a perfect candidate for the modifications we are planning to execute.

The look we are going for is a ‘Lakester’ look with the owner having in mind the inspiration of the Rolling Bones style cars.  Here’s the major details of the body’s transformation:

  • the roof will be chopped  3″ at the rear and 3.5″ up front with laying the windshield back to 75 degrees.
  • Laying the windshield back means we wont have to add a section into the middle of the roof to compensate for tapered ‘A’ posts.
  • The rear window will only be chopped 2.5″ and dropped towards the belt line 0.5″,  a nice subtle custom touch that will be generally noticed when pointed out.
  • The build is the rounded out with a roof insert panel grafted in.

The above is a brief outline of the major operations, not accounting for all the ‘behind the scenes’ work, which includes tweaking the upper hinges to compensate raking the windshield back, so that the doors open freely and don’t bind against themselves.

We also had to chop all the garnish moldings, including the internal bracketry.  We needed to chopped the windshield frame.  Lots of work was involved with tapering and definition work on the ‘A’ and ‘B’ posts so the roof chop looks as though it came from the factory that way.

For even more detailed photos on this 32 Sedan build, here is a link to a post on the HAMB.

Ford Sedan before restoration and roof chop

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The body as delivered to The Metal Surgeon’s shop complete with glass, garnish moldings, seats, and the firewall.

 

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Marked out for the 3″ roof chop.

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Chopped and TIG welded back together, now ready for metal finishing.

Completed roof chop from the rear

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….and metal finished.

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Showing the amount the windshield has to be laid back.

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The whole windshield frame is now removed, and a section grafted in at the base of the frame.

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Weld evidence lines show all the areas that need to be addressed when raking back the windshield.

Completed roof chop from the front

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The 32 Sedan windshield is now metal finished, including the chopped windshield frame and repositioning of the frame hardware/brackets.

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Original garnish molding on the left, and chopped and modified version on the right.

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Garnish moldings fitted with custom brackets made to support the wood after the roof chop was completed.

Keep following this 32 Sedan restoration in part 2 (coming soon)!

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1938 Chevrolet Truck Restoration and Repairs of Metal Work

This 1938 half-ton Chevrolet pickup truck came to our workshop from Texas to have the metal work restoration completed after going through two shops in Houston that failed the owner badly.

Our duties included:

  • making a rear panel for the cab and grafting in
  • restore the right hand fender
  • work on the right hand door
  • clean up the cab as a whole

We also clean up some miscellaneous parts and coated everything in epoxy prior before sending the restored truck back to Houston to a happy customer!

Before restoration – Chevy pickup truck

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The 38 Chevy truck before any restoration work began.

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And a shot from the front of the truck.

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Here’s where things start to go wrong.  The customer took this picture of his cab after the first patch panel was welded in.  You can see the approx size from the photo.

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He took this picture a few months later, then pulled the truck from this shop in Houston.  Apparantely, they were not skilled welders and the first patch panel warped the back of the cab.  So they cut out a larger section, repeat, until there was no back of the cab left.

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This echoes the importance to do your research on a restoration facility’s capabilities.

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The 38 Chevy truck as it came into The Metal Surgeon’s workshop.

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The lower door bottom was cut out and left unfixed by the previous two restoration shops.

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Crude repair on the gas cap opening.

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Area cut out and new material grafted in and metal finished.

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Lower door section fabricated, along with hanging the door, to achieve the appropriate door gapping.

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TIG welded and metal finished.  Door restoration completed.  

Chevy truck fender restoration

 

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Right hand fender as it came into the shop. Caked in filler along with a section cut out.

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The whole side of the fender was weakened pretty badly. The side was made from fresh sheet metal, including the wired edge and then TIG welded into the original fender.

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Side view of the fender section made.

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….and metal finished to completion.

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Another shot of the 38 fender after restoration.

Restoration process of the back of the cab

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Templates made off the rear of the 38 truck cab. The sheet metal blank was divided into a grid to aid template checking. This ensures a good fit for a panel this large.

A panel this large takes skill to make, we made it using the power hammer, which makes the job go pretty quick.

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Ready to graft in.

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Held in position with clecos, ready to be welded in.

Final restoration of the back of the cab

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The cab is now TIG welded and metal finished. Ready to be shot in epoxy primer.

Check out our other posts on the restoration of another 1938 Chevy truck, the Pepsi truck!

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Lower Grille Panel: 1938 Chevrolet Pepsi Truck Custom Build Part 11

This is part eleven of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated.  In post two, we look at the individual truck parts that make up the front end build In post three, we cover the chassis build and drip rail removal In post four, we show you the process of metal finishing the fenders. Post five takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel.  Post six takes care of the lower cowl metal and left hand front fender.  Post seven covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels.  Post eight looks at how the custom hood was created to open by pulling forward instead of the original butterfly design.  Post nine covers the rest of the custom hood, which involves completion of the skin, and design and fabrication of the inner structure.  Post ten shows the firewall modifications.

In this post, we remake an original panel that is rotted out and the only replacement available is in fiber glass, which isn’t going to work for the customer, or fit with this type of build.  The alternative is to make one from scratch (flat sheet metal) using the rotted out panel as a pattern.
Check out the photos below, as we make the panel from scratch with the aid of the sand bag, plannishing hammer, and English wheel for total shape definition.

 Chevy truck lower grille shell before restoration

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Original rotted panel is now serving us as a pattern.

Fabricating a new grille shell panel

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Blocking out with a wooden mallet and a sandbag.

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Plannishing hammer in use.

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Pattern progress check.

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Smoothing up and defining with the English bench wheel.

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New to old….

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Fitting to the original grille.

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Chevy truck grille shell restoration completed

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The end result looking smooth.

 

This is part eleven of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated.  In post two, we look at the individual truck parts that make up the front end build In post three, we cover the chassis build and drip rail removal In post four, we show you the process of metal finishing the fenders. Post five takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel.  Post six takes care of the lower cowl metal and left hand front fender.  Post seven covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels.  Post eight looks at how the custom hood was created to open by pulling forward instead of the original butterfly design.  Post nine covers the rest of the custom hood, which involves completion of the skin, and design and fabrication of the inner structure.  Post ten shows the firewall modifications.

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Exterior metal finishing: 1953 Porsche 356 Cabriolet Part Five

This is part five of a series of posts covering the restoration of this 1953 Porsche 356 Cabriolet, taking us through the final metal finishing of the body.  The introduction post on this Porsche 356 restoration shows pictures of how the Porsche came to us, then after dismantle was complete, and then after the body was media blasted.  Post two covered the beginning of the nose rebuild, leaving the new section TIG welded into position.  Part three looked at how the rest of the front end of the Porsche was repaired.  Part four described how the restoration of the floors and inside cab was accomplished.

Exterior metal finishing is now complete and ready for the bodywork.  We used wax and grease remover to highlight the level of metal finishing we strive to achieve.

Enjoy the pictures and updates to follow.

Metal restoration on a 1953 Porsche 356

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Completed metal work restoration on a 1953 Porsche 356

Wax and grease remover used as highlighting fluid in these photos.

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Stay in touch to see the car in paint!

This is part five of a series of posts covering the restoration of this 1953 Porsche 356 Cabriolet, taking us through the final metal finishing of the body.  The introduction post on this Porsche 356 restoration shows pictures of how the Porsche came to us, then after dismantle was complete, and then after the body was media blasted.  Post two covered the beginning of the nose rebuild, leaving the new section TIG welded into position.  Part three looked at how the rest of the front end of the Porsche was repaired.  Part four described how the restoration of the floors and inside cab was accomplished.

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Floors and Inside Cab: 1953 Porsche 356 Cabriolet Part Four

This is part four of a series of posts covering the restoration of this 1953 Porsche 356 Cabriolet, takes us through the completion of the nose rebuild and work on the front fender.  The introduction post on this Porsche 356 restoration shows pictures of how the Porsche came to us, then after dismantle was complete, and then after the body was media blasted.  Post two covered the beginning of the nose rebuild, leaving the new section TIG welded into position.  Part three looked at how the rest of the front end of the Porsche was repaired.

In this post, we take care of restoration of the floors and inside cab.
We were able to buy reproduction rear floors and jacking points for this 1953 Porsche, but unfortunately the front battery tray panel is not available.  Therefore, we had to fabricate a new one using the decayed original tray as a pattern.  We always look for reproduction panels first, before making any new sections, even if the repro panels need a little tweaking, it still saves the customer on labor costs.

Porsche Floor Before Restoration

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Overview of the damage to the front floor and battery tray of the 356.

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Rough damage.

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Damaged/decayed battery panels which will be used as a pattern.
Braced sections will be straightened out and grafted back in.

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Porsche Floor Repairs

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The hand fabrication of the new battery tray panel.

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Lower section here completely removed for rebuild.

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Shot of the bracing (put in place before anything was cut away).

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Using clecos to hold new panels in position.

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Battery bracket detail:  Removing the battery spring attachment from the original decayed bracket and grafting it into the new.

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Original spring detail, now grafted into the new metal panel.

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Fabricating a new floor section for the 356.

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Newly made floor sections, now tacked into position.

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Welding in a new ‘off the shelf’ jacking point.

Photos of Porsche Floor Restoration Completed

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The new floor panels are now welded in and metal finished.

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Finished off with seam sealer.

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Cleaned up and ready for the next stage.

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Final shot of the completely restored floor of this 1953 Porsche 356.

This is part four of a series of posts covering the restoration of this 1953 Porsche 356 Cabriolet, takes us through the completion of the nose rebuild and work on the front fender.  The introduction post on this Porsche 356 restoration shows pictures of how the Porsche came to us, then after dismantle was complete, and then after the body was media blasted.  Post two covered the beginning of the nose rebuild, leaving the new section TIG welded into position.  Part three looked at how the rest of the front end of the Porsche was repaired.

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Rear End Rebuild: Part 2 1959 Porsche 356A Restoration

This is part of series of posts on this 1959 Porsche 356A’s restoration, Part One introduces us to the problem.

Our first picture shows the lock mechanism.  This post highlights why we are removing the outer section to get to the inner section.  The top lip of the inner sheet metal had been previously repaired badly, it wasn’t aligned with the lock.  The lock was in the right position because it closed properly, so we had to fix the lip panel.

 Rear end removed from Porsche 356A

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The rear section of the Porsche has now removed to begin the inner rebuild.

 

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The rest of the car, with out the rear end.

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The position of lock receiver here highlights the incorrect inner sheet metal.

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This shows the poor inner repairs.

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And the other side of the inner body.

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A view from the side angle, again highlighting the poor inner sheet metal repairs, to be corrected during this restoration.

 

This is part of series of posts on this 1959 Porsche 356A’s restoration, Part One introduces us to the problem.

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Paint Signal Orange: Part 8 Converting a 1972 Porsche 914 to a 914-6 GT

This is Part 8 of a series on the conversion of a 914 to a 916-6 GT Porsche. In Part 1 of this 1972 Porsche 914 restoration/conversion to a 914/6 GT race car, we show the car after media blasting and outlined all the work that we will be completing. Part 2 covers the restoration starting with the rear quarter replacement and alignment.  Part 3 explained how the original fenders were removed and the new flared fenders were set in line.  Part 4 shows the final steps in grafting in the rear fenders.  Part 5 explains how the front fenders were grafted in.  Part 6 looks at the rocker panel transformation from a steel non 914-6 GT rocker into a custom rocker panel.  Part 7 shows photos of the car in primer, ready for paint.

This post shows photos of the 914-6 GT in Glasurit Signal Orange.  We tested Tangerine Orange as well, and Signal came out the winner.  The rockers and bumpers will be a semi-gloss black to complete the racing look.  The under body is Signal Orange in a custom blend with under body textured coating.

Porsche 914-6 GT restoration in paint

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Under coating done in signal orange as well.  This was a custom blend with Porsche textured under body.

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Porsche 914-6 GT rockers and bumpers

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This is Part 8 of a series on the conversion of a 914 to a 916-6 GT Porsche. In Part 1 of this 1972 Porsche 914 restoration/conversion to a 914/6 GT race car, we show the car after media blasting and outlined all the work that we will be completing. Part 2 covers the restoration starting with the rear quarter replacement and alignment.  Part 3 explained how the original fenders were removed and the new flared fenders were set in line.  Part 4 shows the final steps in grafting in the rear fenders.  Part 5 explains how the front fenders were grafted in.  Part 6 looks at the rocker panel transformation from a steel non 914-6 GT rocker into a custom rocker panel.  Part 7 shows photos of the car in primer, ready for paint.

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Primer: Part 7 Converting a 1972 Porsche 914 to a 914-6 GT

This is Part 7 of a series on the conversion of a 914 to a 916-6 GT Porsche. In Part 1 of this 1972 Porsche 914 restoration/conversion to a 914/6 GT race car, we show the car after media blasting and outlined all the work that we will be completing. Part 2 covers the restoration starting with the rear quarter replacement and alignment.  Part 3 explained how the original fenders were removed and the new flared fenders were set in line.  Part 4 shows the final steps in grafting in the rear fenders.  Part 5 explains how the front fenders were grafted in.  Part 6 looks at the rocker panel transformation from a steel non 914-6 GT rocker into a custom rocker panel.

This post just gives a bunch of photos of the car in primer, ready for color.

Photos of Porsche restoration in first stage primer

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Second Prime Photos of 914-6 GT Porsche Restoration

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This is Part 7 of a series on the conversion of a 914 to a 916-6 GT Porsche. In Part 1 of this 1972 Porsche 914 restoration/conversion to a 914/6 GT race car, we show the car after media blasting and outlined all the work that we will be completing. Part 2 covers the restoration starting with the rear quarter replacement and alignment.  Part 3 explained how the original fenders were removed and the new flared fenders were set in line.  Part 4 shows the final steps in grafting in the rear fenders.  Part 5 explains how the front fenders were grafted in.  Part 6 looks at the rocker panel transformation from a steel non 914-6 GT rocker into a custom rocker panel .

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Custom rocker panel fabrication: Part 6 Converting a 1972 Porsche 914 to a 914-6 GT

This is Part 6 of a series on the conversion of a 914 to a 916-6 GT Porsche. In Part 1 of this 1972 Porsche 914 restoration/conversion to a 914/6 GT race car, we show the car after media blasting and outlined all the work that we will be completing. Part 2 covers the restoration starting with the rear quarter replacement and alignment.  Part 3 explained how the original fenders were removed and the new flared fenders were set in line.  Part 4 shows the final steps in grafting in the rear fenders.  Part 5 explains how the front fenders were grafted in.

This post looks at the rocker panel transformation from a steel non 914-6 GT rocker into a custom rocker panel .

A fiberglass 914-6 GT rocker panel is on the market, but no one makes a steel version.  Since this Porsche is all steel, it makes sense to continue that theme by making these custom rocker panels.  It is really a matter of fabricating something that looks good and works with all the shapes of the car.  These custom rocker ends are built with two locating bolts to make the panel a solid feature, along with the factory bolts running along the longitudinal.  We think the rocker panels maintain the factory look, with the jacking points still in place.

There is still some internal custom work to follow, since we have the oil cooler lines running internally through the inside of the passenger rocker panel, along with a new oil cooler under the hood.

Rocker panel before conversion

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How the regular 914 rocker panel starts out.  Flat from end to end, as it was made for a non GT model.

 

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Here shows the rocker panel next to the new flared wheel arch, where shape needs to be added.

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Another shot of the original rockers on the 914.

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And one without the rocker panels on.

Final photos of custom made 914-6 GT rocker panels to match flared fenders

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End tip of the rocker panel,  now with added shape.

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A shot of the front tip of the custom rocker panel.

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Shape transformation.

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Profile lines.

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A shot looking down the body.

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An overview of the Porsche with the custom rocker panel.

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One last shot of the curved tip of the rocker and the new flared fender.

This is Part 6 of a series on the conversion of a 914 to a 916-6 GT Porsche. In Part 1 of this 1972 Porsche 914 restoration/conversion to a 914/6 GT race car, we show the car after media blasting and outlined all the work that we will be completing. Part 2 covers the restoration starting with the rear quarter replacement and alignment.  Part 3 explained how the original fenders were removed and the new flared fenders were set in line.  Part 4 shows the final steps in grafting in the rear fenders.  Part 5 explains how the front fenders were grafted in.