Customs 1938 Zephyr 4dr sedan to 2dr kustom convertible conversion

Thought id share my newest project like i need another one but definetly enjoying all the metalshaping and hand made panel making.

I started out with a pretty crappy 1938 zephyr 4 door sedan that all the goodies where robbed from it so i was able to get it mega cheap. ive always wanted a convertible zephyr but they are way out of my price range so i figure ill just make my own. This is what i started out with


after getting it into the shop i started taking measurements of some of the other zephyrs in the shop to figure out where i need to start trimming and get down to a good foundation to start making panels, i cut off everything i knew was not gonna be needed leaving some extra behind just incase

 

after getting things trimmed down i have a 39 zephyr coupe in the shop i made patterns off of to transfer over to the panels i will making for this conversion. i made a exterior wire form buck of the catwalk off the 39 and check to see how it flows on the 38 zephyr sedan, i also borrowed the 39 decklid for this mock up. i will be making my own decklid aswell

 

A After getting a external pattern off the 39 i then was able to make a internal wire form that i can use on the car while i shape my panels, i also got a flexible shape pattern off the car for easy guidance while shaping.

 

This is going to be good. Thanks for taking us for a ride!

 

Wow, just super that you are providing pics and narratives as you go. Only wished I had 1/10th of your abilities! and guts to cut up a Zephyr.

 

Oh, damn.
And I love the art adorning your shop walls.

 

I'm in

 

Great Stuff - love the work! That catwalk should be super long and cool looking . . .

 

What a craftsman you are!

 

OMG.


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Makes it nice to have a pattern 5 feet away

 

Awesome!

 

Nothing like a quick and easy project - Ha! Being able to take an idea and make it into reality is terrific

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Sweeeet! Ya got some skills boy! Thanks for sharing.

 

Looks good so far! I love these kinds of builds. That is one beefy looking English wheel frame!

Also, how are you making that flexible template? I assume it's made of some kind of tape, but if so, how do you get it off of the part you're templating without tearing it to shit? I could see how that would be a helpful thing to make.

 

Kinda like this maybe ?

 

Thanks buddy, much much more to come

 

Thanks, i love art work and i feel like im in my own brain in there haha

 

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Thank you,I extended it compared to the stock 1938 convertible catwalk

 

I didn't know there were that many Zephyrs left. You must have 'em all in your shop.

 

im more on the tradional styled cars but low, i did this photoshop of what im after. color may change and also the front wont be up so high but i did change a few other things on it in this rendering and i love how it still looks stockish.

 

haha!!! i have a serious zephyr problem.

 

Referring to post #24, I could definitely catch that problem!

 

after wheeling out my sail panels ill need to make the new upper zephyr convertible trunk lid opening being that its very different from the sedan. i made paper patterns off the 39 deck lid opening and made them in 2 pieces as you can see in the pics its a nice tight fit. this will also allow me to trim back my catwalk panels to correct length .

 

Metal shaping around curves is pure genius...

 

upper trunk lid panel really gives the car the look in the correct direction and fits nice. the catwalk panel will be trimmed back a little more for welding and access hammer, dolly and planishing machines.

 

Wow.....inspirational!

 

Thanks for letting us watch, fella, this will be a huge convertible. amazing!