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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. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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..

    PXL_20201012_215643524.jpg PXL_20201012_194833426.jpg PXL_20201012_202409495.jpg PXL_20201012_220030626.jpg PXL_20201012_221625613.jpg PXL_20201012_221632879.jpg
     
    chryslerfan55, Stogy, Jet96 and 8 others like this.
  2. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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.

    PXL_20201012_234848508.jpg PXL_20201013_001247854.jpg PXL_20201013_001225565.jpg PXL_20201013_183219765.jpg PXL_20201013_183207870.jpg
     
  3. Marty Strode
    Joined: Apr 28, 2011
    Posts: 5,149

    Marty Strode
    Member

    Paul, it's hard to beat good old American tools !
     
    Stogy, loudbang, Paul and 2 others like this.
  4. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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.

    PXL_20201013_200906987.jpg PXL_20201013_192041665.jpg PXL_20201013_193108639.jpg PXL_20201013_193541714.jpg PXL_20201013_203649621.jpg PXL_20201013_204239152.jpg PXL_20201013_211458340.jpg PXL_20201013_212301304.jpg PXL_20201013_221603170.jpg PXL_20201013_224422332.jpg PXL_20201014_000609725.jpg PXL_20201014_012230577.jpg PXL_20201014_012305782.jpg
     
  5. Outback
    Joined: Mar 4, 2005
    Posts: 1,158

    Outback
    Member
    from NE Vic

    Looking good!
     
    Stogy, loudbang and Paul like this.
  6. Nice work, as always Paul.
     
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  7. A Boner
    Joined: Dec 25, 2004
    Posts: 5,729

    A Boner
    Member

    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!
     
  8. OFT
    Joined: Jun 1, 2005
    Posts: 539

    OFT
    Member

    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!
     
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  9. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    Thanks man, that's quite a compliment.
     
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  10. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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..

    PXL_20201014_233124171.jpg PXL_20201015_001616510.jpg PXL_20201015_004200685.jpg PXL_20201015_011859658.jpg PXL_20201015_012017346.jpg PXL_20201015_012024475.jpg
     
  11. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    same procedure for front Z metal

    PXL_20201016_200255904.jpg PXL_20201016_213112115.jpg PXL_20201016_231100939.jpg PXL_20201016_224728494.jpg PXL_20201016_230049978.jpg
     
  12. alchemy
    Joined: Sep 27, 2002
    Posts: 15,868

    alchemy
    Member

    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.
     
  13. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    If I was paying myself the going hack shop rate I'd be rich... or broke..
     
  14. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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..

    PXL_20201017_230649184.jpg PXL_20201017_232909246.jpg PXL_20201018_000127591.jpg PXL_20201018_002229945.jpg PXL_20201018_004458453.jpg PXL_20201018_005155503.jpg
     
  15. Marty Strode
    Joined: Apr 28, 2011
    Posts: 5,149

    Marty Strode
    Member

    Paul, The Z-metal fillers are an excellent idea, great execution as well.
     
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  16. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    Thanks Marty.
     
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  17. Jet96
    Joined: Dec 24, 2012
    Posts: 1,175

    Jet96
    ALLIANCE MEMBER
    from WY

    Paul -I really appreciate you taking the time to take photos. I know how hard it is to stop and do that!
     
  18. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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.

    PXL_20201018_203740931.jpg PXL_20201018_203802442.jpg PXL_20201018_225720789.jpg PXL_20201018_233902674.jpg PXL_20201018_234655779.jpg PXL_20201018_234640710.jpg
    PXL_20201019_011958155.jpg
     
  19. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    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..

    PXL_20201020_233005016.jpg PXL_20201020_222531644.jpg PXL_20201020_222659707.jpg PXL_20201020_223028514.jpg PXL_20201021_014200995.jpg PXL_20201021_022058975.jpg
     
    chryslerfan55, Stogy, Tim and 16 others like this.
  20. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    Two, near mirror image.. PXL_20201021_182944097.jpg
     
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  21. bchctybob
    Joined: Sep 18, 2011
    Posts: 2,502

    bchctybob
    ALLIANCE MEMBER

    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.
     
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  22. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    all three top pieces resting roughly in place

    PXL_20201021_191028244.jpg
     
  23. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    Trim and tack

    PXL_20201021_200224076.jpg
    PXL_20201021_235200535.jpg
    PXL_20201021_235141218.jpg
    PXL_20201021_235151302.jpg
    PXL_20201021_232334100.jpg
     
    J_J2, chryslerfan55, Stogy and 16 others like this.
  24. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    TIG
    File
    Sand

    PXL_20201024_001520138.jpg PXL_20201024_005921941.jpg PXL_20201024_012802918.jpg PXL_20201024_012822476.jpg PXL_20201024_011047243.jpg
     
  25. flatheadgary
    Joined: Jul 17, 2007
    Posts: 818

    flatheadgary
    Member
    from boron,ca

    and people complain about the structure one must make for fiberglass bodies. although the glass body gets pretty heavy afterwards.
     
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  26. The 39 guy
    Joined: Nov 5, 2010
    Posts: 2,876

    The 39 guy
    Member

    Great work ! Great thread!
     
  27. 64 DODGE 440
    Joined: Sep 2, 2006
    Posts: 4,155

    64 DODGE 440
    ALLIANCE MEMBER
    from so cal

    Keeps getting prettier.
     
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  28. Paul
    Joined: Aug 29, 2002
    Posts: 15,025

    Paul
    Editor

    This is my third T build.

    First was cute
    Second was nice
    This one is is pretty

    Do I see a trend here?
     
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  29. I bet that made a world of difference in how stiff it is. Looks great, too!
     
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  30. lake_harley
    Joined: Jun 4, 2017
    Posts: 1,099

    lake_harley
    Member

    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
     

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