Projects '23 Ford Roadster build aka The Incredible Hulk

Started cowl/firewall support.
Used stock firewall as a pattern and bent some 3/4" square tube to match.
Trimmed the flange back to leave about 1/2" around the opening,
clamped the tube in place and tacked and trimmed the legs.
I'm thinking 1/4" polished aluminum firewall attached with chrome carriage bolts..

 

Lots of starts but all will come together..

Started the bend for the channel.
Body will be channeled over the frame 2-1/2".
'tried to bend a 4' length of 18 gauge..
The long brake might make a nice long bend in Christmas wrap but 18 gauge steel, not so much..
Hard on both ends and soft in the middle..
So I used the old Chicago and bent four 2' pieces.
They need a bend mid length anyway to follow the frame rails.

 

Paul, it's hard to beat good old American tools !

 

Upon closer examination the lower edge of the body driver side forward was deemed too rusty to suffice.
So...
Back to:
Cut, roll, break, shrink, stretch and roll.
Check shape by placing piece upside down on opposite side and match.
Scribe, trim, clamp and tack.
Skip weld 1/2" +/- until it's fully welded.
Clean it up and bump it into shape..
Not perfect but,
remember it's just an old Model T, nothing special,
they made millions of them
Heck, you could buy a used one for the price of a new hat.
Set the body back on the chassis,
now there is something to weld to.

 

Looking good!

 

Nice work, as always Paul.

 

Sure a labor of love. With most people not having your skills or equipment, and the relatively low cost, it’s obvious why there are so many Tupperware T’s that have been built over the years. Keep up the fantastic rescue, and killer build!

 

I have been impressed with your skills for years! Figured it was about time to post some of my admiration. Keep up the progress and pictures. Thank you for posting so I can follow along!

 

Thanks man, that's quite a compliment.

 

Trimmed two pieces of Z metal I bent up the other day,
Drilled the bent flange at bottom body edge every 2" more or less,
clamped them in place
plug welded
body back on to check fit..

 

same procedure for front Z metal

 

Paul, I'm going to send you my T roadster panels in a flat crate and you let me know when it's ready to pick up.

 

If I was paying myself the going hack shop rate I'd be rich... or broke..

 

Filling the gaps at rear corners
No patterns, just cut, bend, shrink
and plug weld to the skin
like the Z metal at the sides
Times two..

 

Paul, The Z-metal fillers are an excellent idea, great execution as well.

 

Thanks Marty.

 

Paul -I really appreciate you taking the time to take photos. I know how hard it is to stop and do that!

 

Short day in the shop today.
Worked on the driver front corner of body,
where it needs a notch to clear the steering box and pitman arm
Trimmed the body back just enough to clear,
bent up and tacked in some 1/4" round stock
along the raw edge.
Also bent a test piece of sheet metal
but that will need to be revisited,
'not too keen on fit or design.

 

Worked on the top rail a little
Set up shrinker/stretcher close to work
Cut a strip of 18 gauge steel
Break
Shrink and stretch
Hand planish
Touch it with a DA..
I can see how this might work..

 

Two, near mirror image..

 

I've been thinking of doing that to my '28 roadster body. Lots of cracks and old repairs up along that edge. Seems like a vulnerable area. Great work! Keep those pictures coming Paul.

 

all three top pieces resting roughly in place

 

Trim and tack

 

TIG
File
Sand

 

and people complain about the structure one must make for fiberglass bodies. although the glass body gets pretty heavy afterwards.

 

Great work ! Great thread!

 

Keeps getting prettier.

 

This is my third T build.

First was cute
Second was nice
This one is is pretty

Do I see a trend here?

 

I bet that made a world of difference in how stiff it is. Looks great, too!

 

I might have seen the answer to my question in post number 444, but do you use TIG on all of the sheet metal work you've done? Or, do you sometime tack with MIG and then do the finish welds with TIG? No matter what your process, and maybe it varies from panel to panel, the workmanship is always enviable.

Lynn