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Projects '23 Ford Roadster build aka The Incredible Hulk

Discussion in 'The Hokey Ass Message Board' started by Paul, Feb 22, 2018.

  1. Love that bead around the shock mount! Great detail & thanks for sharing the tooling to make it!
     
  2. Marty Strode
    Joined: Apr 28, 2011
    Posts: 5,005

    Marty Strode
    Member

    Paul, the bead roller tech is pure genius ! That's going to be a great car.
     
  3. Nicholas Coe
    Joined: Jul 5, 2017
    Posts: 1,573

    Nicholas Coe
    ALLIANCE MEMBER
    from Tontitown

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  4. 51box
    Joined: Aug 31, 2005
    Posts: 912

    51box
    Member
    from MA

    Really clever idea for that notch piece!
     
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  5. Perfect work, flawless Paul.
     
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  6. loudbang
    Joined: Jul 23, 2013
    Posts: 29,899

    loudbang
    Member

    NICE tight radius on that bead. :)
     
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  7. Moriarity
    Joined: Apr 11, 2001
    Posts: 18,587

    Moriarity
    SUPER MODERATOR
    Staff Member

    pure genius......
     
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  8. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    E brake handle bracket
    Make cardboard into steel
    hack original bracket
    Weld two together

    IMG_20200611_132001.jpg IMG_20200611_115811.jpg IMG_20200611_171023.jpg
    IMG_20200611_155357.jpg
     
    Last edited: Jun 11, 2020
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  9. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    pulled the rear today
    welding the brackets to the housing
    cleaned inside the housing
    straightening the housing
    reassembling the rear swapping the 3.08 posi for the 3.42 posi
    pressed the left hand thread studs from the left axle and pressed some right hand thread studs in their place
    the rear back in the car

    it will have to come out again to go through the pumpkin, axle bearings, seals, brakes etc.
    but it's all welded and straight

    IMG_20200618_094638.jpg IMG_20200618_112918.jpg IMG_20200618_134010.jpg IMG_20200618_141226.jpg IMG_20200618_142732.jpg IMG_20200618_142746.jpg IMG_20200618_145206.jpg IMG_20200618_162231.jpg IMG_20200618_162220.jpg
     
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  10. Paul, curious about how far off the rear housing was after the welding and your process for straightening. Could you elaborate a bit. I am going to be visiting this issue with my 9 inch this fall.
     
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  11. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    The ladder bar and spring brackets get welded all the way around.
    I break the circumference into quarters,
    weld one quarter then the opposite quarter,
    then between the end of the first weld to the start of the second weld ,
    then the end of the second to start of the first. All traveling in the same direction.
    This balances out the heat warp somewhat.
    Most of the heat warp here was caused by the shock mounts having heat concentrated on one side of the tube.
    You can see it in the fourth picture.
    There is about a 1/16" gap at about 10:00.
    I heated the tube in about a dime sized spot opposite the shock mount to cherry red and quenched the spot with a wet rag.
    Checking movement after it was cool enough to rest my hand on the spot.
    Repeated that adjacent to that spot.
    That seemed to square the end up pretty good but it needed to move over more so I heated a spot inboard of the ladder mount,
    Then above and below that one. You can see where I heated the spots in the sixth picture.
    Again moving slowly and checking between each heat/cool cycle.
    Until the end bushing just slips into the axle bearing seat. Seen in the fifth picture.
    Both sides reacted about the same.
    I picked up the kit years ago at a 4x4 swap meet with bushings to fit a 9" Ford rear.
    Later I had bushings made to fit the Olds center.
    I cut the center with a grinder to make it a little easier to work with.

    All pretty basic hot rod stuff.
     
    Last edited: Jun 20, 2020
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  12. Thanks for tutorial Paul. Makes a lot of sense and very helpful. Already feel better about tackling my 9 inch:)
     
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  13. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    dang, where does the time go?
    been busy doing non car stuff,

    finally got a couple hours in on the old Hulk
    dug out the last of my Olds/Pontiac brake junk
    picked the best drums and backing plates,
    blasted them and shot them with Zero-Rust non flat,
    because that's what I had..

    IMG_20200630_091323.jpg
     
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  14. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    I like the look of the straight up early windshield
    but it's too rough
    thought I'd try some later, '25ish stanchions and lower frame,
    because I have them and they are in a bit better shape.
    the stanchions lean back a few degrees
    but the lower frame is a bit short.
    so I hacked up a spare upper frame to use a donor
    and extended the vertical legs on the original
    to make it about 3-3/4" taller
    and chopped the tops off the stanchions to fit
    IMG_20200702_122501.jpg IMG_20200702_122745.jpg IMG_20200702_123219.jpg IMG_20200702_125747.jpg IMG_20200702_140437.jpg IMG_20200702_140441.jpg IMG_20200702_141807.jpg IMG_20200702_141828.jpg
     
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  15. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    swapped the dirt tires for street with caps borrowed from the '27
    and rolled it out for a walk around.
    it's very important to stand back and check the overall look
    every step of the way
    before it's all set in stone.

    IMG_20200702_161718.jpg IMG_20200702_161517.jpg IMG_20200702_161909.jpg IMG_20200702_161854.jpg IMG_20200702_161826.jpg IMG_20200702_161736.jpg IMG_20200702_161454.jpg IMG_20200702_161433.jpg
     
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  16. That thing is the business @Paul!
     
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  17. Moriarity
    Joined: Apr 11, 2001
    Posts: 18,587

    Moriarity
    SUPER MODERATOR
    Staff Member

    pure genius!!!
     
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  18. Dick Stevens
    Joined: Aug 7, 2012
    Posts: 2,862

    Dick Stevens
    Member

    The visual is magnificent!
     
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  19. 31Apickup
    Joined: Nov 8, 2005
    Posts: 2,189

    31Apickup
    ALLIANCE MEMBER

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  20. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    Thanks guys!
     
  21. Old-Soul
    Joined: Jun 16, 2007
    Posts: 3,564

    Old-Soul
    Member

    I for one appreciate the "unconventional" use of OEM shocks.
    In a world of guys running off the shelf Monroe shocks, Paul is living in style.
     
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  22. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    Thanks, I do like the ride quality of hydraulic verses gas charged.
     
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  23. I’d never seen this photo of Gene Chan’s car until it popped up on IG today so I thought I’d post it here! CB73DCDD-11C3-4619-AE43-10A05260A8BF.jpeg
     
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  24. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

  25. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    I have three relatively straight but rusty doors,
    If a better one doesn't turn up soon one of them will have to be fixed.

    IMG_20200704_131829.jpg
     
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  26. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    I need a decent door before stitching the body together.

    I need the body panels at least tacked together before the floor gets fabbed.

    But should locate the pedals and battery box before the floor..

    Sounds like it's time to work on brake and clutch pedals..

    IMG_20200706_185812.jpg
     
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  27. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    Nah, I'll work on the pedals later.

    so I started fixing on the door.
    Of the three, I chose the one that came on the Hulk.
    Missed a photo op but cut a piece of 20 gauge steel,
    and used the English wheel to put a slight crown in it.
    Made a paper pattern following the inside of the bead
    and transferred that to the steel and rolled a bead around.
    Bent up an outer door piece.
    Blasted the door where the new will meet the old
    and cut the rusty stuff away.
    Clamped the new behind the old and scribed it to cut for butt joint.
    Tacked it in place.
    Tacked the new outer part to the door.
    Welded all.
    started hammer/dolly/filing...

    It's going to take a bit of work to make it nice
    but it should be ok..
    enough..

    That's it for today..

    IMG_20200706_155628.jpg IMG_20200706_155807.jpg IMG_20200706_160324.jpg IMG_20200706_160512.jpg IMG_20200707_111001.jpg IMG_20200707_122029.jpg IMG_20200707_122036.jpg IMG_20200707_122401.jpg IMG_20200707_123137.jpg IMG_20200707_123920.jpg IMG_20200707_135355.jpg IMG_20200707_135931.jpg IMG_20200707_143334.jpg IMG_20200707_165611.jpg IMG_20200707_165618.jpg IMG_20200707_165624.jpg IMG_20200707_175225.jpg IMG_20200707_181548.jpg
    IMG_20200707_184725.jpg
     
  28. Paul
    Joined: Aug 29, 2002
    Posts: 14,888

    Paul
    Editor

    Stole an hour to get out to the shop
    Cleaning up work done on the door
    Still looking for a nice original but
    this one is just about ready for fitting.

    IMG_20200708_161845.jpg
     
  29. Stogy
    Joined: Feb 10, 2007
    Posts: 16,737

    Stogy
    ALLIANCE MEMBER

    :rolleyes:...T-riffic job...;)
     
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  30. alchemy
    Joined: Sep 27, 2002
    Posts: 15,673

    alchemy
    ALLIANCE MEMBER

    I've got a pile of those doors. How many you need?




    Just kidding. Nice work!
     

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