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Projects Norwegian Zephyr Roadster Kustom

Discussion in 'Traditional Customs' started by Mats-Henrik, Sep 16, 2013.

  1. Mats-Henrik
    Joined: Nov 7, 2009
    Posts: 94

    Mats-Henrik
    Member
    from Norway

    Thanks, it means alot!

    I've been working on the other side the last few days. Without the fenders this is really an ugly beast:

    <a href="http://www.flickr.com/photos/101906403@N07/10265673313/" title="zepher 252 by matsheinrich, on Flickr">[​IMG]</a>
    <a href="http://www.flickr.com/photos/101906403@N07/10265564066/" title="zepher 253 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10265572495/" title="zepher 255 by matsheinrich, on Flickr">[​IMG]</a>


    I did a quick mockup to keep the motivation up, I think its going somewhere.
    <a href="http://www.flickr.com/photos/101906403@N07/10341395105/" title="zepher 264 by matsheinrich, on Flickr">[​IMG]</a>


    That brought me to the grille again. I've got three different grille sets for it, but all of them are in pretty poor condition. The top one looks to be original, the one in the middle appears to be home made, and the one in the bottom looks like an old aftermarked unit.
    <a href="http://www.flickr.com/photos/101906403@N07/10341398325/" title="zepher 262 by matsheinrich, on Flickr">[​IMG]</a>
    <a href="http://www.flickr.com/photos/101906403@N07/10341587453/" title="zepher 263 by matsheinrich, on Flickr">[​IMG]</a>

    I do like some patina on old parts, but these are all in too bad condition to use I'm afraid. Let me know if anyone has one in better condition laying aroung!
     
    Last edited by a moderator: Jun 1, 2014
  2. COUPES
    Joined: Feb 24, 2013
    Posts: 171

    COUPES
    Member
    from England

    The middle one looks like it was an oven grill? Great work Mats!
     
  3. gnichols
    Joined: Mar 6, 2008
    Posts: 11,345

    gnichols
    Member
    from Tampa, FL

    Magical. Nice work. Gary
     
  4. srs244
    Joined: May 24, 2013
    Posts: 12

    srs244
    Member

    man, what great work and workmanship. fabulous!! thanks for sharing the progress and the pictures. it's going to be a great ride once completed.
     
  5. skooch
    Joined: Feb 7, 2007
    Posts: 245

    skooch
    Member

    Those grills are very fragile. On my zephyr I drilled small holes and used pop rivets and small sheets of metal to hold the broken pieces together. Also I rechromed them which I later regretted because they lost that cool patina you mentioned.
     
  6. ss34coupe
    Joined: May 13, 2007
    Posts: 4,239

    ss34coupe
    Member

    Incredible work!
     
  7. F&J
    Joined: Apr 5, 2007
    Posts: 13,222

    F&J
    Member

    Mats, Do you know if other years will be the same? I have a lead for a pair, in real nice condition. I will measure and take some pics.

    I am not sure if the seller will want to ship overseas, but I can ask.<!-- / message -->
     
  8. Mats-Henrik
    Joined: Nov 7, 2009
    Posts: 94

    Mats-Henrik
    Member
    from Norway

    I havent thought of that, I thought the material was to fragile to repair. Did you take any pictures of the prosess?


    Yeah, they´re one year only. Let me know what the seller says!
     
  9. I love the 38 grilles. The only Zephyr with horizontal grille bars. The grilles are quite fragile, and I've never come across a set without a few broken bars.

    The 38 Zephyr I just sold had its original grilles, but bad broken bars on each side.
     
  10. skooch
    Joined: Feb 7, 2007
    Posts: 245

    skooch
    Member

    Here is my "repaired grill" I did around 4 of these and some are less noticeable than others. The break that looks huge in this picture is really not that noticeable when viewing the car under normal circumstances.
     

    Attached Files:

  11. cleatus
    Joined: Mar 1, 2002
    Posts: 2,277

    cleatus
    Member
    from Sacramento

    Look into wether there is an artist's foundery somewhere near you.
    If so, you can epoxy the grill pieces together as best as you can, and then use that as the master to have them create a plaster mold from it and re-cast it for you.
     
  12. cederholm
    Joined: May 6, 2006
    Posts: 1,748

    cederholm
    Member

    WOW!! What a great build.

    ~ Carl
     
  13. Mule Farmer
    Joined: Jun 1, 2005
    Posts: 1,508

    Mule Farmer
    Member
    from Holland MI

    Wouldn't the new be smaller than the original dew to shrinkage.


    Nice build by the way. I have a 40 four door my self. Im planing on making it into a two door. Im going to get a coupe top and doors this week end.
     
  14. F&J
    Joined: Apr 5, 2007
    Posts: 13,222

    F&J
    Member

     

    Attached Files:

    kidcampbell71 likes this.
  15. That looks like a 39 grille. I may be interested if its for sale...
     
  16. Mats-Henrik
    Joined: Nov 7, 2009
    Posts: 94

    Mats-Henrik
    Member
    from Norway

    Yup, that looks like a 39. Thanks anyway!


    Posted using the Full Custom H.A.M.B. App!
     
  17. Mats-Henrik
    Joined: Nov 7, 2009
    Posts: 94

    Mats-Henrik
    Member
    from Norway

    The car is now ridiculously high up in the air, but I guess wheel well clearance won't be an issue when I finally get to lower it. I can't wait to get it closer to the ground, but I keep telling myself to have all the welding and leading done before I lower it.

    <a href="http://www.flickr.com/photos/101906403@N07/10531869905/" title="zepher 265 by matsheinrich, on Flickr">[​IMG]</a>

    I'm working on the passenger side these days, I had to redo the rear upper part of the door to get everything lined up correctly. I hate to cut up my own work to do it over again, but sometimes you just have to.
    <a href="http://www.flickr.com/photos/101906403@N07/10531950825/" title="zepher 276 by matsheinrich, on Flickr">[​IMG]</a>

    Next up was molding the rear passenger fender. I always get to carried away working to take pictures during the prossess, but its pretty straight forward, using as many as possible of the old mounting holes to get the fender in right place before welding it. I also used some extra self tapping screws to get the gap between the body and fender as small as possible.

    To get the rear lamps lined up correctly I used a pretty crued method, but it worked. After alot of adjusting and measuring it was time to weld.

    <a href="http://www.flickr.com/photos/101906403@N07/10531803805/" title="zepher 266 by matsheinrich, on Flickr">[​IMG]</a>

    To get a nice flow between the fender and body I used a 1" metal strip. I considered making it 2", but I think its nice to have a litte "contour" left.
    <a href="http://www.flickr.com/photos/101906403@N07/10532043293/" title="zepher 267 by matsheinrich, on Flickr">[​IMG]</a>
    <a href="http://www.flickr.com/photos/101906403@N07/10532041483/" title="zepher 268 by matsheinrich, on Flickr">[​IMG]</a>
    <a href="http://www.flickr.com/photos/101906403@N07/10531815286/" title="zepher 269 by matsheinrich, on Flickr">[​IMG]</a>
    <a href="http://www.flickr.com/photos/101906403@N07/10532035923/" title="zepher 271 by matsheinrich, on Flickr">[​IMG]</a>

    It was nice to see that the fenderskirt lined up pretty good with the fender without any work.

    <a href="http://www.flickr.com/photos/101906403@N07/10532033983/" title="zepher 272 by matsheinrich, on Flickr">[​IMG]</a>

    I also got started on leading up the front fender. Cant wait to get all the leading done!

    <a href="http://www.flickr.com/photos/101906403@N07/10532194163/" title="zepher 274 by matsheinrich, on Flickr">[​IMG]</a>
     
    Last edited by a moderator: Jun 1, 2014
    kidcampbell71 likes this.
  18. Eric H
    Joined: Apr 2, 2006
    Posts: 972

    Eric H
    Member

    Looks fantastic!
     
  19. Nice work and progress, Mats!
    Pictures are great, but I hope I'll get time to see it live again soon :)

    Sent from my HTC One S using H.A.M.B. mobile app
     
  20. J.B.
    Joined: Jan 7, 2005
    Posts: 1,246

    J.B.
    Member
    from Sweden

    Looks great! Time for a 1940's style kustom meeting in Scandinavia soon? :D
     
  21. Wensum Valley Rods
    Joined: Oct 13, 2008
    Posts: 289

    Wensum Valley Rods
    Member
    from England

    Looking good Mats, how low are you lookjing to go with the rear end ? I straightened the rear crossmember on mine and got it down to a lovely ride height , trouble is the chassis hit the top of the axle tubes when it was loaded with gas and driven. I am now about to start a small c notch of the chassis to overcome the problem.
    Great to see that you are starting to lead it up, make sure you clean that tinning flux of really good with hot soapy water and lots of baking soda.It corrodes (flash rusts) like crazy if not and is a bitch to get back under control (ask me how I know).

    Paul.
     
  22. Mats-Henrik
    Joined: Nov 7, 2009
    Posts: 94

    Mats-Henrik
    Member
    from Norway

    I'm in! I'm hoping to get it up and running by next season. I did that last fall also, but alot of other things got in the way. Uddevalla is about 1,5 hours drive, so I have my hopes up for A-bombers next year!

    To get it as low as I want, I'll have to get it down 8 inches in the rear. That is quite a lot, and the norwegian equivalent to the DMV dont allow the frame to be altered, so first I'll get it as low as I can with de-arching, removing a some leafes and reversing the eyes, as well as longer shackles. What you say about the axle hitting the frame is bad news for me, but I'll have to figure something out.

    You're always welcome, as long as you bring cold beer :)
     
  23. Mats-Henrik
    Joined: Nov 7, 2009
    Posts: 94

    Mats-Henrik
    Member
    from Norway

    I cleaned up the rear end last night. One thing I really envy you guys in the US (at least a major part of the US) is the lack of rust on projects. As I mentioned early in this thread, I started out doing alot of rust repair. There is a lot of details that are hard to predict, and you just have to repair most places back to original, wich would be fine if you are restoring an old car, but I'm making a kustom. So then you have to go back, and cut open parts you've put hours and hours in making, to get the car the way you want. But look at the bright side, I could be wasting my time in front of the TV or at a sporting event..

    So, here is the story of the rear end in pictures:

    <a href="http://www.flickr.com/photos/101906403@N07/10553597166/" title="zepher 284 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10553596406/" title="zepher 285 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10553595426/" title="zepher 286 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10553594806/" title="zepher 287 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10552634364/" title="zepher 278 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10552590406/" title="zepher 280 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10552628824/" title="zepher 281 by matsheinrich, on Flickr">[​IMG]</a>

    <a href="http://www.flickr.com/photos/101906403@N07/10552824883/" title="zepher 282 by matsheinrich, on Flickr">[​IMG]</a>

    Finally its done.. I hope.
     
    Last edited by a moderator: Jun 1, 2014
  24. Finnrodder
    Joined: Oct 18, 2009
    Posts: 2,970

    Finnrodder
    Member
    from Finland

    Great work again!
     
  25. F&J
    Joined: Apr 5, 2007
    Posts: 13,222

    F&J
    Member

    nice fitting work on that new panel:cool:
     
  26. Outback
    Joined: Mar 4, 2005
    Posts: 2,381

    Outback
    Member
    from NE Vic

    Wow what an inspiration!

    Posted using the Full Custom H.A.M.B. App!
     
  27. Hemiken
    Joined: Sep 21, 2012
    Posts: 492

    Hemiken
    Member
    from Australia

  28. flynbrian48
    Joined: Mar 10, 2008
    Posts: 8,220

    flynbrian48
    Member

    Can you use air bag springs? A buddy of mine has a bag set up design he built on his '36 Ford Woody, that would work on your Zephyr. I can connect you guys if you think that would pass your motor vehicle code guys. It's a bolt in deal.

    Brian


    And, your build is incredible. Great vision, you're turning that ugly duckling into a swan.

    QUOTE=



    To get it as low as I want, I'll have to get it down 8 inches in the rear. That is quite a lot, and the norwegian equivalent to the DMV dont allow the frame to be altered, so first I'll get it as low as I can with de-arching, removing a some leafes and reversing the eyes, as well as longer shackles. What you say about the axle hitting the frame is bad news for me, but I'll have to figure something out.



    You're always welcome, as long as you bring cold beer :)[/QUOTE]
     
  29. Eric H
    Joined: Apr 2, 2006
    Posts: 972

    Eric H
    Member

    Do you think they would notice if you flattened the rear crossmember in a factory looking way? Pic stolen from Wensum Valley Rods build.
     

    Attached Files:

  30. J.B.
    Joined: Jan 7, 2005
    Posts: 1,246

    J.B.
    Member
    from Sweden

    I'm afraid there must be a kickup to allow the axle to move without hitting the frame. Any chance on doing that factory looking? I must do that damn kickup on my LaSalle as well, but I don't have a tranverse leaf spring.
     

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