This is part nine of a classic restoration series of posts on this highly custom 1938 Chevrolet Truck classic restoration, in post one of classic restoration we introduce you to the project and the custom features to be fabricated.  In post two of classic restoration, we look at the individual truck parts that make up the front end build.  In post three of classic restoration, we cover the chassis build and drip rail removal.  In post four of classic restoration, we show you the process of metal finishing the fenders. Post five of classic restoration 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 of classic restoration takes care of the lower cowl metal and left hand front fender.  Post seven of classic restoration 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 of classic restoration looks at how the custom hood was created to open by pulling forward instead of the original butterfly design.

 

This post finishes out the aluminum work on the custom hood which involves completion of the skin, and design and fabrication of the inner structure, which is the bonded to the outer with a 2-part epoxy (Lord Fusor 112B medium or slow).

Whilst on the inner structure topic we can cover the hood sides as well, shown in the pictures below. The inner hood sides are then spot welded to the outer skin using a Pro-Spot PR10.

1938 Chevrolet Truck classic restoration

Hood outer skin completed, it was created in one piece instead of the original butterfly style.  Now we are ready for the inner structure to be built.

Outer hood in open, functioning mode.

Inner hood structure designed and fabricated to give strength to the outer skin.

Installation of inner in progress.

Onto the hood sides inner structure design and build.

Hood sides inner structure being spot welded into position.

Hood side offered into position to double check fit.

 

Completed hood sides in first stage primer.

Close up details.

 

This is part nine of a series of posts on this highly custom 1938 Chevrolet Truck classic 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.