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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. nrgwizard
    Joined: Aug 18, 2006
    Posts: 1,614

    nrgwizard
    Member
    from Minn. uSA

    Thanks for the detail pics on body work + strengthening.
    Profile looks good.
    Marcus...
     
    loudbang likes this.
  2. patmanta
    Joined: May 10, 2011
    Posts: 3,801

    patmanta
    ALLIANCE MEMBER
    from Woburn, MA
    1. MASSACHUSETTS HAMB

    What type of wood mallet are you using? Are you using a woodworking mallet or something like a shellfish mallet?

    I was taught that a wood dolly goes a long way with shrinking but the one I made myself was too soft so I didn't get very far with it and haven't revisited the high spot on my cowl in a long time.
     
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  3. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Niether, in fact it was a cheap leather crafting mallet

    I was looking for a heavier one but found this one first.

    I checked the local thrift store for a wooden baseball bat to make my own but all they had were aluminum.. old hickey sticks probably have too much grain anyway.
    The hardware stores had plastic hammers but no wood, I wanted to strike while the iron was still hot so..
    headed for a kitchen supply store but pulled into a craft store and found this one first.
     
    The 39 guy, Stogy, patmanta and 2 others like this.
  4. patmanta
    Joined: May 10, 2011
    Posts: 3,801

    patmanta
    ALLIANCE MEMBER
    from Woburn, MA
    1. MASSACHUSETTS HAMB

    Gocha, thanks! I may try a crab mallet out. I use hickory hammer handles where I can but they really only work against a pronounced curve. I was taught to use those forming pieces against static dollies and forming heads; they worked great for that but are tough to make much headway against body panels sitting on a car, at least for me so far.
     
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  5. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Spent a couple days working on the floor.
    Made a cardboard pattern for the kick,
    transfered that to some 18 gauge steel,
    rolled some beads in it,
    drilled it for plug welding and body to frame bolt access,
    and welded it in.

    PXL_20201119_004409356.jpg PXL_20201119_005918583.jpg PXL_20201119_181701861.jpg PXL_20201119_191752164.jpg
     
    Tim, sko_ford, Stogy and 10 others like this.
  6. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Put a few more pieces of floor bracing in to frame the master cylinder and battery access holes,
    made some more cardboard patterns,
    douched the rocker areas with Ospho,
    let that dry over night and painted the areas with some rust preventive paint,
    transfered the patterns to steel and followed the roll, drill, weld routine.
    Ground the welds flush and hit it with the DA.
    That brings us up to date.

    PXL_20201120_002138567.jpg PXL_20201119_223255672.jpg PXL_20201120_191635369.jpg PXL_20201120_191547763.jpg PXL_20201120_201230227.jpg PXL_20201120_204207804.jpg PXL_20201120_220458918.jpg IMG_20201120_172743_861.jpg
     
    Jet96, patmanta, Stogy and 14 others like this.
  7. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Back corners in and tunnel started..

    IMG_20201121_165641_990.jpg
     
    bct, patmanta, Stogy and 16 others like this.
  8. The 39 guy
    Joined: Nov 5, 2010
    Posts: 3,250

    The 39 guy
    Member

    Great craftsmanship!
     
    Stogy, loudbang and Paul like this.
  9. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Thanks man
     
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  10. Marty Strode
    Joined: Apr 28, 2011
    Posts: 6,735

    Marty Strode
    Member

    An inspiration to all !
     
    34 5W Paul, Stogy, loudbang and 3 others like this.
  11. Tman
    Joined: Mar 2, 2001
    Posts: 36,064

    Tman
    ALLIANCE MEMBER

    Those rear inside corners are killer!
     
    Atwater Mike, loudbang and Paul like this.
  12. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Wasn't going to work on the car today..
    Couldn't quite stay away,
    the fit of the tunnel bugged me
    so I bent up another and welded it in.

    PXL_20201123_012805507~2.jpg
     
    Stogy, El Hueso, 51box and 9 others like this.
  13. I have a T with turtle deck queued up and while mine will never be as well built as yours, I appreciate you setting such a great example. Love the stance and details!
     
  14. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    You can do anything you set your mind to.
    Believe it.
     
  15. Great work! That thing is going to be stout! Can you explain a little bit on how you crafted the tunnel?
     
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  16. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Thanks man, yeah like a real car only smaller.

    Sorry I didn't take pictures of the process.

    I made a profile template of the shape using a strip of scrap steel
    Cut a piece of sheet a little over sized,
    about an inch longer and wider than needed
    Clamped a length of 2" pipe to the steel table using some scrap sheet metal a little thicker than the tunnel metal as shims at each end of the pipe to create a gap between the pipe and table to feed the sheet through.
    Gradually bending the tunnel metal by hand until the bend radius matched the profile template.
    Bent both edges on the sheet metal break
    Rough cut the rear of the tunnel to approximately the right angle.
    Held the tunnel in place and scribed a more accurate cut line.
    Trimmed the angle cut, scribed a line parallel to the cut the width of desired flange.
    Bent the flange with a pair of pliers working slowly along the line.
    Smoothed the bend using hammer on metal table edge.
    Used the shrinker and stretcher to correct the angle flange.
    Smoothed the edge with hammer and table edge again.
    Drilled 3/16" holes along flanges every two inches give or take.
    And welded it in.
    First one took about an hour, second one was much faster.
     
    Atwater Mike, patmanta, Stogy and 9 others like this.
  17. Thanks @Paul! And thank you for taking the time to share all the tech info that has gone into this build.
     
  18. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    PXL_20201125_225211258~4.jpg
    PXL_20201125_225252062~2.jpg
     
    Last edited: Nov 25, 2020
    Just Gary, brEad, RodStRace and 14 others like this.
  19. Dave G in Gansevoort
    Joined: Mar 28, 2019
    Posts: 1,186

    Dave G in Gansevoort
    Member
    from Upstate NY

    2nd thread binge, 2nd time I'm convinced I need to sell all my shop tools and find another hobby. This is such a great build, keep it up and post more!
     
  20. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Made some cardboard templates of the transmission hump and toe board,
    transfered that to some 18 gauge steel,
    rolled beads in the toe board piece,
    bent the transmission hump same way I bent the tunnel,
    drilled and spot welded the hump to the toe board,
    cut the hole for the E brake.
    Still need to make the patch for the pedal area and drill and tap to screw it all in place.
    The hump and toe board will be removable as one for access and ease of body removal.

    PXL_20201128_014025844.jpg PXL_20201128_014230226.jpg PXL_20201128_234740974.jpg PXL_20201129_003950483.jpg PXL_20201129_021735179.jpg PXL_20201129_203015832.jpg PXL_20201129_213652652.jpg IMG_20201129_164955_898.jpg
     
  21. gonzo
    Joined: Dec 24, 2003
    Posts: 1,818

    gonzo
    Member

    Every new post provides a new reason to love this build. So clean and well executed.
     
    cactus1, patmanta, OFT and 4 others like this.
  22. loudbang
    Joined: Jul 23, 2013
    Posts: 40,113

    loudbang
    Member

    Very CLEAN looking floor parts. :)
     
    Paul and Stogy like this.
  23. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Cut and rolled some tin to cover the holes at steering/pedals, master cylinder and battery
    The battery lid will get a hinge and latch, the master will get pins and a screw and the steering/pedal patch will get screws.

    PXL_20201201_220143499~2.jpg PXL_20201201_225525124.jpg PXL_20201201_225453532.jpg PXL_20201201_231859860.jpg PXL_20201202_000819989.jpg
    PXL_20201202_004000647.jpg
     
    Last edited: Dec 1, 2020
    Just Gary, bchctybob, brEad and 11 others like this.
  24. OFT
    Joined: Jun 1, 2005
    Posts: 560

    OFT
    Member

    Paul, your craftmanship is always a treat to see!
     
  25. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    thanks man

    I'm OK with the patch around the steering column and pedals
    but the master cylinder access cover got out of square while rolling one end
    and the bead layout in the battery access cover bugs me..

    I will attempt to redo them today.
     
    Stogy and loudbang like this.
  26. The 39 guy
    Joined: Nov 5, 2010
    Posts: 3,250

    The 39 guy
    Member

    To bad you will be covering up all of that beautiful metal work. I am glad you shared the process of making the floor and supporting structures with us though. It's a great foundation for a high quality Hot Rod!
     
  27. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Rerolled the out of square end of master cover
    And built and installed a new battery cover
    this time smooth with no beads.

    PXL_20201202_191216728.jpg PXL_20201202_212949456.jpg PXL_20201202_212910250.jpg
     
    Last edited: Dec 2, 2020
    bct, brEad, kidcampbell71 and 10 others like this.
  28. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Tunnel, toe board, master and pedal covers screwed to floor framework.

    PXL_20201204_003302309.jpg
    PXL_20201204_003804857.NIGHT.jpg
     
    bchctybob, warbird1, brEad and 14 others like this.
  29. Dick Stevens
    Joined: Aug 7, 2012
    Posts: 3,315

    Dick Stevens
    Member

    loudbang and The 39 guy like this.
  30. Paul
    Joined: Aug 29, 2002
    Posts: 15,751

    Paul
    Editor

    Well then, I guess whatever covers it
    better look better than that.. ;)
     
    chopndrop, kidcampbell71, OFT and 4 others like this.

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