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Projects 38 LINCOLN ZEPHYR COUPE

Discussion in 'Traditional Customs' started by oztinbasher, Jun 3, 2014.

  1. oztinbasher
    Joined: Aug 16, 2013
    Posts: 81

    oztinbasher
    Member
    from oz

    One of my customer asked me last year if I could make a roof for a zephyr coupe if he bought it, and we discussed the details and he ended up buying it. This is what turned up at Christmas.
    [​IMG]
    [​IMG]
    I started on it in febuary and squared it up and put some bracing in. I hacked off the windscreen header and window frames. It had been chopped about 8” and the workmanship was very poor. Over lapped panels and the roof was oxy cut off, there was even body washers welded in to fill holes.
    [​IMG]
    I used a 38 ford sedan roof to make up part of the roof and back window, but it was to narrow and the gutter was different to the zephyr even though it comes from the same ford family.
    [​IMG]
    [​IMG]
    You can see in this shot it was looking a bit to raked in the roof, and I didn’t want a steel car looking like one of fibreglass kit cars. So we lifted the windscreen a bit and clipped another ½” out of the back window, we had a stock front garnish mould so we worked out we had a 5” chop.
    [​IMG]
    Next I had to fix the window frames.
    [​IMG]
     
    Lines and ausbuick like this.
  2. Dear god! I hope this comes out as well as it could.
     
  3. PKap
    Joined: Jan 5, 2011
    Posts: 592

    PKap
    Member
    from Alberta

    You are a brave one for taking this on. I always wonder at the p.o. of cars like this; trying to chop a zephyr without a clue... Makes me shake my head


    Posted using the Full Custom H.A.M.B. App!
     
  4. oztinbasher
    Joined: Aug 16, 2013
    Posts: 81

    oztinbasher
    Member
    from oz

    Next I had to make the door frames, they were made from 3 parts. One was a L shape and curved with the stretcher, the second was a Z section shrunk on the inner edge and stretched on the outer flange to make the curve, and the last part was cut to the final curved shape of the back of the frame.
    [​IMG]
    [​IMG]
    Next was the gutter which started as a strip with a 90 bend and the other end bent over 120 degrees with a 3/8” radius. I then made a profile tool set of the gutter to go in the Pullmax, I run the part through the Pullmax a couple of times, stretching it to the shape of the door.
    [​IMG]
    Then it was a matter of just making patches to fill the gaps that looked the right shape and making it the same on the other side.
    [​IMG]
    [​IMG]
    [​IMG]
    The B pillar shape had to be changed as a 5” chop is going to change the roof shape and since we didn’t have roof anyway?
    [​IMG]
    [​IMG]
    [​IMG]
     
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  5. ebfabman
    Joined: Mar 10, 2009
    Posts: 620

    ebfabman

  6. williebill
    Joined: Mar 1, 2004
    Posts: 2,454

    williebill
    Member

    Wow! Great work, looks good.
     
  7. Wolfman1
    Joined: Jul 8, 2010
    Posts: 265

    Wolfman1
    Member

    Nice save !!
    Can't believe someone would cut up a Zephyr that bad
    You're a brave guy to tackle it and it looks great now
     
  8. brady1929
    Joined: Sep 30, 2006
    Posts: 8,076

    brady1929
    Member

  9. ss34coupe
    Joined: May 13, 2007
    Posts: 4,066

    ss34coupe
    Member

    Very nice work! Looking forward to seeing more of this build.
     
  10. Nice work, how about a feature on the roadster parked next to it as well?
     
  11. SIC-E-NUF Kustoms
    Joined: Dec 1, 2012
    Posts: 3

    SIC-E-NUF Kustoms
    Member
    from Salinas Ca

    Wow hats off to mister.This is one challenge a lot of people would of even tried to attempt let alone succeed.Great craftsmen ship.And gotta love a zephyr!!


    Posted using the Full Custom H.A.M.B. App!
     
  12. I would have looked at that and said "Carson Top" ... great work to save it.
     
  13. UNSHINED 2
    Joined: Oct 30, 2006
    Posts: 948

    UNSHINED 2
    Member

    Nice save! I may have attempted that on my own car, but to do it for a customer without having a template takes balls...
     
  14. ausbuick
    Joined: Jan 31, 2011
    Posts: 676

    ausbuick
    Member

    I'm staying tuned for sure.
     
  15. Holy shit Steve.. this looks rad! First time i've seen pics of Richards Zepher.. sure looks as rough as Dick and Curly said it was!
     
  16. awesome work thus far Steve, great to see.
    Cheers,

    Drewfus
     
  17. Eric H
    Joined: Apr 2, 2006
    Posts: 962

    Eric H
    Member

    Great save, it amazes me that a car like that could have wound up in the hands of such hacks.
     
  18. Obviously the car is in very capable hands . Very nice work !
     
    Peanut 1959 likes this.
  19. Nice stuff !!

    I cant for the life of me figger out why you'd whack a 38 Zephyr.....aaarrghhhh
     
  20. Roger O'Dell
    Joined: Jan 21, 2008
    Posts: 1,061

    Roger O'Dell
    Member

  21. pwschuh
    Joined: Oct 27, 2008
    Posts: 2,216

    pwschuh
    Member

    I really like where this is headed. Glad he bought it and put it in your capable hands.
     
  22. Wensum Valley Rods
    Joined: Oct 13, 2008
    Posts: 288

    Wensum Valley Rods
    Member
    from England

    Nice save. Definitely seems the previous owner got in way to deep. Glad it's all coming back together.
    Gotta love these old Zephyrs. :)

    Paul.
     
  23. HOLY CRAP! What a terrible thing to do to one of the coolest cars ever!
    I am in awe, literally at your amazing skills and the fact you could save it from the previous butchery! Unbelevable!
    I really wish I had one tenth the skills and abilities of guys like you!
    Great work, keep us posted.
     
  24. oztinbasher
    Joined: Aug 16, 2013
    Posts: 81

    oztinbasher
    Member
    from oz

  25. Very impressive work. I can't wait to see more.
     
  26. Your a patient and talented man. I thought roadster for sure at the beginning.
     
  27. woodbutcher
    Joined: Apr 25, 2012
    Posts: 3,153

    woodbutcher
    Member

    :eek: Damn.Someone needs to arrested for rape.Good save.
    Good luck.Have fun.Be safe.
    Leo
     
  28. oztinbasher
    Joined: Aug 16, 2013
    Posts: 81

    oztinbasher
    Member
    from oz

    Thanks Guy's,
    Starting on the rust repairs now, the edge on the blue guard where it bolts on was rusted and had a poor repair, and where it bolts to the running board was blended with a large radius. So I made it match the other rear guard.
    [​IMG]
    And knocked out a few dents.
    [​IMG]
    One of the spats was rusty and the other looked like it had been run over. Made a patch for the back corner and used a shrinking disc to straighten the other.
    [​IMG]
    Cheers Steve
     
  29. 29ToyA
    Joined: Oct 29, 2010
    Posts: 413

    29ToyA
    Member

    Great save!
     

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