Tag Archives: antique cars

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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.

 

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Front fender flare grafting: Part 5 Converting a 1972 Porsche 914 to a 914-6 GT

This is Part 5 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.

Moving to the front of the car where we graft in the front GT panels.  It’s the same process as the rear fenders, with a little shape change.  Completing the front fender graft, completes the GT conversion, as far as the exterior metal work goes.

Next we will look at  the rocker panel conversion to marry up with the GT arches.

 

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Removal of the original fender in process.

 

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Original 914 fender panel removed.

 

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All four original fenders removed and in very good condition.

 

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914-6 GT fender panel set with clecos into position, after careful alignment in ‘body line.’

 

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914-6 GT fender panel now tack welded into position.

 

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TIG welded, plannished, and filed, now ready for the last stage where it’s wiped clean with an abrasive disc.

 

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Front 914-6 GT fender TIG welded and metal finished.

 

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Front angle of the Porsche, proportional and and muscular.

 

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Nice transforming shape.

 

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Ready for high build primer.

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.

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Front End: 1953 Porsche 356 Cabriolet Part Three

This is part three 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.

The first few pictures in this post show the front end completion process to the way it looked when leaving the factory.

We next head around the corner to the right hand fender where the panel just like the rest of the body has seen a reasonable amount of filler work, not deep by any means, just enough to create its fair share of ‘lows,’ which we’ll bring up by hand, with our standard metal finishing process, in preparation for the high build primer process.

The great thing about this Porsche 356 is there is almost zero rust around the exterior, that’s compliments to the owner for taking care of the car for the last 50 years!

Continue to enjoy future posts as we complete the exterior metal work.

 Completion of Porsche nose rebuild

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Hood damage highlighted here.
 

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Smooth….
 

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Another angle of the nose.
 

Front fender restoration – Porsche 356

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Beginning stage of the left hand fender repair, showing signs of damage.
 

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View from the opposite angle before restoration work.
 

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Typical damage from ‘grounding.’
 

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Area smoothed out and skimmed with lead immediately in front of the fender support bracket.
 

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Hammer,dolly and file work in progress.
 

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Repairing the original lead area around the door aperture.
 

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Nose, left hand fender, and hood are now restored.
 

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We are now ready for primer.
 

This is part three 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.

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Firewall and cowl build: 1938 Chevrolet Pepsi Truck Custom Build Part 10

This is part ten 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.

This post will show the original firewall modifications, mainly by lowering the distributor depression, and then filling in the void above with an aluminum close out panel, that will be bonded to the original firewall.

The close out panel fabrication involves using the Baileigh bead roller to create raised areas to give a factory Chevrolet look.

The final set of photos show the cowl bead build process, to correct poor metal structure from the original one, to round out the metal work on the front of the Chevrolet cab.

Firewall panel fabrication

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Original firewall face.

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Since this build will have a modern 350 Chevrolet engine, we can lower the firewall depression.

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Welded in and metal finished.

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To make the firewall more interesting we made a close out panel. Here’s the beginning of making the template.

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Tracing the template to the aluminum sheet.

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Sheet metal perimeter cut out and offered up to the firewall.

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Bead work in progress with our Baileigh equipment.

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Close up of bead work.

Completed firewall panel

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Cowl Metal Work

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Previous cowl top was damaged and weak from the media blasters so we made a new section to graft in.

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Profile/ side view from hood to style line.

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Grafting in and TIG welding stage.

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Onto the metal finishing stage.

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Close up profile view of the finished product.

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sheet metal fabrication, custom metal worker, metal work denver, antique cars, automotive repair, automotive restoration, car body repair, classic cars, metal working, chevrolet, custom car, restoration, vintage cars

Finally, the overview of the completed cowl.

This is part ten 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.