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

Discussion in 'The Hokey Ass Message Board' started by SKOTY CHOPS KUSTOMS, Jan 30, 2018.

  1. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    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 20180129_212654.png 20180129_212728.png 20170107_132149.jpg 20180129_212715.png


    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
    20180129_212743.png
     
    plan9, kiwijeff, ClarkH and 6 others like this.
  2. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

  3. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    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

    20180129_213153.png 20180129_213138.png 20180129_213211.png
     
  4. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    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. 20180129_213315.png
    20180129_213751.png 20180129_213808.png 20180129_213913.png
     
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  5. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

  6. m.kozlowski
    Joined: Nov 2, 2011
    Posts: 113

    m.kozlowski
    Member

    This is going to be good. Thanks for taking us for a ride!
     
    SKOTY CHOPS KUSTOMS likes this.
  7. 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.
     
  8. xpletiv
    Joined: Jul 9, 2008
    Posts: 937

    xpletiv
    Member
    from chiburbs

    Oh, damn.
    And I love the art adorning your shop walls.
     
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  9. Bored&Stroked
    Joined: Jan 14, 2005
    Posts: 4,014

    Bored&Stroked
    ALLIANCE MEMBER

    Great Stuff - love the work! That catwalk should be super long and cool looking . . .
     
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  10. BJR
    Joined: Mar 11, 2005
    Posts: 4,606

    BJR
    Member
    from Minnesota

    What a craftsman you are!
     
  11. OMG.


    Sent from my iPhone using H.A.M.B.
     
    SKOTY CHOPS KUSTOMS likes this.
  12. Makes it nice to have a pattern 5 feet away
     
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  13. GordonC
    Joined: Mar 6, 2006
    Posts: 1,114

    GordonC
    ALLIANCE MEMBER

  14. Jalopy Joker
    Joined: Sep 3, 2006
    Posts: 20,480

    Jalopy Joker
    Member

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

    Sent from my SM-G930V using The H.A.M.B. mobile app
     
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  15. spurgeonforge
    Joined: Oct 18, 2013
    Posts: 385

    spurgeonforge
    Member

    Sweeeet! Ya got some skills boy! Thanks for sharing.
     
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  16. Squablow
    Joined: Apr 26, 2005
    Posts: 13,301

    Squablow
    Member

    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.
     
  17. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    Thanks buddy, much much more to come
     
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  18. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    Thanks, i love art work and i feel like im in my own brain in there haha
     
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  19. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    i e
    Thank you,I extended it compared to the stock 1938 convertible catwalk
     
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  20. Atwater Mike
    Joined: May 31, 2002
    Posts: 8,591

    Atwater Mike
    ALLIANCE MEMBER

    I didn't know there were that many Zephyrs left. You must have 'em all in your shop. :eek::D
     
  21. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    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. 38 ZEPH black  CHOPPED-02.jpeg
     
  22. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    haha!!! i have a serious zephyr problem.
     
    Skankin' Rat Fink likes this.
  23. Atwater Mike
    Joined: May 31, 2002
    Posts: 8,591

    Atwater Mike
    ALLIANCE MEMBER

    Referring to post #24, I could definitely catch that problem!
     
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  24. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    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 20180129_213628.png 20180129_213643.png 20180129_213701.png .
     
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  25. Atwater Mike
    Joined: May 31, 2002
    Posts: 8,591

    Atwater Mike
    ALLIANCE MEMBER

    Metal shaping around curves is pure genius...
     
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  26. SKOTY CHOPS KUSTOMS
    Joined: Jan 9, 2007
    Posts: 797

    SKOTY CHOPS KUSTOMS
    Member
    from BAY AREA

    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.
    20180129_213733.png 20180129_214003.png
     
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  27. oldrelics
    Joined: Apr 7, 2008
    Posts: 1,729

    oldrelics
    Member
    from Calgary

    Wow.....inspirational!
     
    chryslerfan55 likes this.
  28. 40two
    Joined: Feb 19, 2012
    Posts: 1,548

    40two
    ALLIANCE MEMBER

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

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