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Projects Converting 1934 Ford 4D Sedan to 3W Coupe

Discussion in 'Traditional Hot Rods' started by Kontra, Oct 30, 2022.

  1. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Hi all

    Greetings from Finland.
    Here is my long journey to convert my 1934 Ford 4D Sedan (or some parts of it) to 3W Coupe!

    It is difficult to write about your own car. It makes things more difficult also the fact that the entire story spans more than 10 years. Some of the details must have evaporate from my head. Any way one goal, or dream is now true – a 1934 Ford 3W – is at my garage now!
    (And sorry my "not so perfect English)

    During years I found some guys on the internet that had made a standard four-door Ford Sedan to a five-window coupe. In the pictures it looked really easy. Of course there would be a lot of work!

    October 2010
    I got a phone call from my friend Tommi. He told me that he got '34 Sedan roof and rear doors laying around. "It is cheap, he says".
    I asked will it fit in my Volkswagen Transporter Van? Sure, said Tommi!
    Well, it didn't fit, so the roof was cut up in smaller pieces at Tommis yard.

    I stored the roof in my backyard several years. I was still working with my A-Coupe, so no time and money to build two cars.
    I found ’33-34 Coupe rear quarters that were made in Sweden at Lazzes sheet metal course
    They were cheap and I bought them. Pieces rested at by backyard until 2014, when I moved to another town, Karkkila, Finland. Situation did not change much at all. Now the parts were lying in the backyard at Karkkila.

    However, I was keeping my eyes open and antennas out to find more parts. I need a cowl and front doors. I tried to buy those parts from Sweden on local websites and Facebook. No luck!
    Then I got a phone number to one Finnish guy who was willing to sell extra cowl to me! Great! That happens in October 2014. Now there was a little more pieces in by backyard bu, not enough!
    I found one 4D Sedan door (outer skin) to the driver side and one Tudor door to the passenger side!
    Now I had enough parts to start the build!!

    It was summer 2016 when I built the frame jig using a 60 x 100 mm beam. Then I placed the frame on top of the jig. The frame was straight so I started to throw body pieces to the frame.… sounds like easy
    Assembling the body on the frame was difficult lack of rear axle. Or I had one empty banjo rearend but there werent brake drumes. So I made the 7.50 x 16 ”rear wheels” out of plywood to imitate rear wheels.

    In the winter of 2016-2017, the car progressed piece by piece. I welded the body together whenever I had time and inspiration.

    In the summer 2017, the basket case was already piled up so much, that I wanted to have the car outside to see what it looks like. I couldn't get a car out with plywood wheels, so I put "search on" for rear brake drums. Then I found complete banjo axle. Same guy was selling a running 21-bolt flathead and three-speed trans. Of course I bought them too!
    20170908_174059.jpg

    I install the rear axle in place and I screwed the wheels. There was already some kind of axle in the front end and wheels in place, so basically the car was rolling.
    20170911_122734.jpg

    It was a little challenging to get the car from the jig alone Somehow it worked out and on September 12, 2017 was the great day!! I rolled the car out from my one car garage! It was very interesting to see what it really looks seen from a little further away.

    It was a totally shit! Awful, Ugly! What ever you want to name it!
    20170915_185256.jpg 20170915_185514.jpg

    The A-pillar is way too upright and the rear part of the roof is also too vertical. Somehow the proportions just didn't match at all!
    Reality hit straight to my face and I pushed the pile back into the garage!.
    At this point, my inspiration disappeared completely.

    I moved it later autumn 2017 to storage, because the A-Coupe new paint was on duty in the winter of 2017-2018. 20171029_115701.jpg

    So stay tuned, this "saga" will continue!!

    Ari Berghäll
    Editor in chief

    PRIMER MAGAZINE

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  2. Squablow
    Joined: Apr 26, 2005
    Posts: 16,265

    Squablow
    Member

    I LOVE these conversions, I'm waiting to hear more!
     
  3. ss34coupe
    Joined: May 13, 2007
    Posts: 4,229

    ss34coupe
    Member

    Look forward to seeing your progress on this build.
     
    panhead_pete likes this.
  4. panhead_pete
    Joined: Feb 22, 2006
    Posts: 3,256

    panhead_pete
    ALLIANCE MEMBER

    Im in. With the soaring prices of 3W model 40 coupes and bodys these builds are particularly interesting.
     
    Outback likes this.

  5. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Part 2

    In this hobby, it's great that you get to know many new people.
    In autumn 2017 At the Yankee Car Show in Lahti, Finland. I talked to one guy who happened to have a similar one project in the middle of Finland. He has bought a fiberglass 3W body as a template to his own project. The body would will be unnecessary at some point. I promised to buy it when it’s free. That date was end of summer 2018.
    20180825_135816.jpg

    In October 2018 I want to see what the car would look with the a fiberglass body on it. I admit, It was close to using a fiberglass body but gritting my teeth, I continued with the steel body.
    20181110_125926.jpg


    In the fall of 2018, I tried to shape Sedan door upper sills to follow new roof curvature. I tried, I cut, I did everything that I can, but the steel doesn’t bend like I wanted! Painful!
    61f1e618-7baa-426b-861c-98a0de15229c.jpg

    Idea in the entire project was that I'm in no hurry, and no schedule. I challenge my skills and I'm trying to learn something new. At this point I had to raise my hands and scream out loud: I can't!

    I was wondering if I buy for an English wheel and other tools for my all ready too small garage. I have to sit down and list the different options:

    Option 1: The car would not be any more ready, even if I buy a garage full of new sheet metal forming machines because I don't know them use!

    Option 2: The project has ”burn” a lot of money, and it looks like shit, anyway. No one wouldn’t pay even half of the money that have spend.

    Option 3: Take the car to a guy who is more professional sheet metal guy than I am.

    I choose option 3!!

    So stay tuned, this "saga" will continue!!

    Ari Berghäll
    Editor in chief

    PRIMER MAGAZINE

    www.primermagazine.fi
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    https://www.youtube.com/channel/UCf4GhpSsUJEFZPOuNk9-EGg
     
    Outback, adam401, 1biggeorge and 11 others like this.
  6. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Okay, folks. Story continues…

    I decided to go with option number three and have a help for person who all ready have all the tools and experience to use them. I contacted one guy who promised to take my project in the winter of 2019. That date moved and moved month after month… It felt like I couldn't get a car never under work.

    In the fall of 2019, I talked to my good friend and Ari Talus about my case. Ari happened to have too much free time, and he was very interested to start project like that! So, I towed the pile to Ari in Lieto, Finland in end of the November 2019
    c3e44a48-d3e7-4234-ad58-a8ccb91d5b8a.jpg 93ee4d7c-2127-4e63-a56e-7605a99dbbcd.jpg

    Ari got down to business right away and at the same week my whatsapp started to pop up project photos. Things started to progress in excellent speed!
    2d314bbb-b618-4a92-a9a1-58de9b7bab23.jpg 935ea715-62cb-46dd-a62c-a2350df86237.jpg 5aadd529-5d9c-43d7-bf1d-35efa613e72f.jpg 08dae773-9dbc-49d3-8dda-afa03fb33e78.jpg 3b92c926-3fcc-4529-a704-06486b7fa22a.jpg e5068388-83e3-4e06-afce-7db3d6bf2b06.jpg

    I delivered a fiberglass body to Ari and it was great to notice, that rough-looking pile is starting to like a complete car!

    On January 20, 2020, I get the car back home from Ari.I was impressed when I saw the car first time outside in one piece. It was absolutely great. Chopping, shape of the rear roof, the tilt of the A-pilars…everything caught my eye very nicely! Absolutely great work and craftmanship!
    20200120_150606.jpg 20200120_150745.jpg 20200120_151109.jpg 20200120_151139.jpg 20200120_152355.jpg


    Ari Berghäll

    Päätoimittaja/Editor in chief


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  7. mtndone
    Joined: Jul 30, 2019
    Posts: 13

    mtndone

    It looks great! thank you for sharing
     
    Kontra likes this.
  8. Squablow
    Joined: Apr 26, 2005
    Posts: 16,265

    Squablow
    Member

    Looks great, proportions are spot-on.
     
  9. oliver westlund
    Joined: Dec 19, 2018
    Posts: 1,686

    oliver westlund
    Member

  10. JimSibley
    Joined: Jan 21, 2004
    Posts: 3,599

    JimSibley
    Member

    This is such a cool Build. A tudor is much easier to make a 3w from. A four door is a natural for a 5w, but you are building what you want from what you have. I love it. Here is a few pics of my pile of parts made into a 3w, as well. 147FD329-7918-4508-8D0B-A1986FDEE825.jpeg 20E57D49-7FCA-4868-BAB4-A142F41B0AD1.jpeg 7876FBDC-5612-406C-AC3D-F8C303D0F64C.jpeg 24DAB012-21A0-4CAB-A37C-93030444D5F9.jpeg
     
  11. Mark Wahlster
    Joined: May 21, 2016
    Posts: 75

    Mark Wahlster
    Member

    Reminds me of some of the builds you see BAD CHAD do but without ending up looking like it was hacked up with a chainsaw and with no thought of design or the lines flowing like they should.

    Yours looks like its going to turn out VERY nice. Just proves persistence pays off in the end. Can't wait to see it all finished with you grinning from ear to ear sitting in the driver seat.
     
    Dwight schneider, Kontra and Tim like this.
  12. 55chevr
    Joined: Jul 12, 2008
    Posts: 967

    55chevr
    Member

    Bad Chad is way out there.
     
    Kontra and Tman like this.
  13. Love builds like this. Keep the updates coming.
     
    Kontra likes this.
  14. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Thanks for the all comments!!

    January 2020
    Metalman Ari had done excellent job, but, there was still a lot of welding and grinding to do. I have to replace firewall, weld Bear Claw locks, chop the windshield frame, adjust the gaps in the doors, repair a few
    rust holes, replace all wooden body supports and made new structure from square tubing, etc… in total for a year of that.
    20210213_093847.jpg 20210213_093924.jpg 20210213_093929.jpg
    20201201_190705.jpg 20201203_185912.jpg IMG_20210131_164743_308.jpg

    The body was completed in February 2021 and I took it to my friend for sandblasting. After that body was sprayed acid paint.
    20210305_140110.jpg

    I sprayed four layers of water-thinned Noxudol soundproofing compound to the body.
    I sprayed it total seven layers to the body. Good and sufficient material! No hum!
    20210328_164311.jpg 20210401_142946.jpg 20210401_145702.jpg

    It was strange to see the body in one color for the first time and I was "forced" to put the body on the frame and take some pictures of it! I already started to test different colors in Photoshop.
    20210404_162643.jpg

    So, the body was ready, and I left it to warehouse to wait painting time. I towed rolling chassis to my home garage. I fabricated boxing plates for 4 mm steel, and welded them to the frame. Then I made new motor mounts, steering box plate, and a new straight rear spring crossmember and millions of othes "small things".
    20210502_131301.jpg 20210508_163904.jpg
    One quite big job was fit ’39 pedals and master cylinder to the chassis! It was surprisingly tricky trying to figure out what is the right distance for the pedals, when the body was missing!
    20210219_164235.jpg 20210220_153116.jpg 20210508_163913.jpg

    I put a 21-bolt first into place, because I wanted to know if it works. There was a rumor that it was running engine when I bought it! That was also true!

    When everything seems to be working I remove all parts of the chassis for a painting. In May 2021, I sprayed the primer to chassis and the gloss black 2-stage car paint. I did paint axles, brake plates, brake parts and more small parts shiny black.
    I wanted to paint all parts with real car paint. No spray can.
    20210514_175643.jpg 20210615_201329.jpg 20210622_183407.jpg

    Ari Berghäll

    Päätoimittaja/Editor in chief


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  15. Squablow
    Joined: Apr 26, 2005
    Posts: 16,265

    Squablow
    Member

    Looks great! What are the inner door skins from?
     
    Kontra likes this.
  16. 57JoeFoMoPar
    Joined: Sep 14, 2004
    Posts: 5,561

    57JoeFoMoPar
    Member

    Impressive work and persistence. Where there is a will, there is a way.
     
    Kontra likes this.
  17. Happydaze
    Joined: Aug 21, 2009
    Posts: 1,436

    Happydaze
    ALLIANCE MEMBER

    Impressive, quite a transformation! I'm loving the irony in modeling a steel body off of a glass one! Ha ha!

    Chris
     
    Kontra and Outback like this.
  18. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Outback, BILL LUPIANO and elgringo71 like this.
  19. micshotrodgarage
    Joined: Sep 20, 2012
    Posts: 99

    micshotrodgarage
    Member
    from colorado

    You guys in the old world really do it right,
     
    Kontra likes this.
  20. BILL LUPIANO
    Joined: Dec 19, 2015
    Posts: 225

    BILL LUPIANO
    ALLIANCE MEMBER
    from Canada

    Great work.Thanks for taking us on the journey.I'm waiting for updates!
     
    Kontra likes this.
  21. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    At the end of November 2021, I got the chassis ready to drive first time! My friend built me totally rebuild 21-stud flatty many years ago. It was on the storage waiting to go between ’34 chassis rails.
    20211104_172954.jpg
    Engine is totally stock, except headers. I had bought a new Stromberg 97, and new Stromberg electronic ignition, new starter, new fuel pump and a new alternator for it. I didn’t want use old parts on these “critical” places.
    20211116_161933.jpg
    20211106_131722.jpg
    One important moment is test drive on a bare chassis! I did it end of the November 2021. I was +2 C outside, but for me it feels like a summer
    20211120_114423.jpg

    I did some minor jobs to the “almost ready” chassis in the December. I had made a schedule, that I should have to take body to the painter right after Chrismas 2021.
    20211213_163317.jpg

    20211215_193953.jpg

    20211219_162523.jpg

    Day before I promised to take body to the painter, I suddenly got an idea to took body from my warehouse, put I to the chassis and drive it before the painting. Sound very wise, but I really want to see (and hear) how it looks and sounds when it’s moving! So, I took the body back home from the warehouse and with the help of my neighbor, we pushed it to the chassis.
    20211220_151128.jpg

    I bolted the doors, and tailgate into the body for a few screws. So, I did a small test run in the snow 27 December! That happened in the morning and couple hours ago at the same day the body left to the painter!!
    20211228_102137.jpg

    20211228_103151.jpg
    For my eyes car looks like it should look! I was happy!

    Ari Berghäll

    Päätoimittaja/Editor in chief


    PRIMER MAGAZINE

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  22. ekimneirbo
    Joined: Apr 29, 2017
    Posts: 3,119

    ekimneirbo

    I'd like to congratulate you on your persistance and a job well done...........:)
     
    Kontra likes this.
  23. Squablow
    Joined: Apr 26, 2005
    Posts: 16,265

    Squablow
    Member

    Looking good so far! Although I hope you didn't drive too far with only 2 nuts holding the front wheels on! Can't wait to see further progress, I really like it.
     
    Outback and Kontra like this.
  24. elgringo71
    Joined: Oct 2, 2010
    Posts: 3,566

    elgringo71
    Member

    Fantastic job, it was definitely worth the effort
     
    Kontra likes this.
  25. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Thanks!!

    Ari
     
  26. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    I just drive few hundred meters and front wheels stays on!! :)
    Ari
     
    Squablow likes this.
  27. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    Thanks a lot!!

    Ari
     
  28. Kontra
    Joined: Apr 27, 2007
    Posts: 25

    Kontra
    Member
    from Finland

    For some reason, when there is a deadline things tend to work out. I signed up to a car show at 1-2 of April 2022. While the body was at the painter I try to do every small things that I could do on driveable chassis. I even take a notebook and I wrote an note if I found something than I can do before the body is back. Of course there was lot of things that I couldn't do until the body was painted.

    Choosing a color to the body was just as much pain in the ass as it always will be. In last hours there were two options: something blue, or dirty yellow. You know how nice it is to make a decision on small color sample…. There weren’t no time to spray some test color, because Markus (the painter) was in a hurry with "real jobs". So…. I decided yellow! Not any typical color for me. I saw one French 5W Coupe on that kind of color on Instagram and that was it! Let's make it yellow!

    Finally, on Friday 11 March 2022, I went to the painter to took the painted body back to home. I took a risk and I have to admit that the color was shock! The yellow was incredibly bright! No can do anymore! A rolling chassis was pushed into the yard and four of my friends threw the body onto the chassis in a few minutes.
    So there was about three weeks to get car ready to the show!!!
    20220311_165053.jpg

    20220311_180507.jpg

    I had agreed on an Jari Kedonperä that he will paint to the body some "competition numbers" and other stuff on Saturday 12 March. In my thoughts it was also possible to do some patina to the paint. It was a pleasure to watch the work of an professional.
    20220312_115147.jpg

    20220312_134933.jpg

    While Jari painted his things, I piled up the body so that I wouldn't be in Jari's way. The competition numbers and other things came ready the same afternoon. We agreed that Jari will continue next Saturday body patination.
    20220313_161807.jpg
    Too bright yellow color bothered me all week no matter how long I was staring at. Jari Kedonperä came next Saturday to continue his magic. After an hour of work, too bright yellow color was a memory. Jari did his "magic treatment" the paint showed exactly what I had thought in my mind – dirty and patinated surface!
    20220319_133843.jpg


    I had promised the car to the exhibition in Tampere, Finland which was organized on 1-2 April 2022. The coupe was show-ready on Thursday 31.3. at 3:30 p.m.
    277743591_3150890215124392_1840702513946773274_n.jpg

    20220505_165143.jpg
    20220403_135507.jpg
    There was only one day i didn't build a car when I cam from a work so late. All other days I was building a car!

    "If there was no deadline, then nothing would ever be finished".

    At the exhibition It was a great surprise, when I won the "Special Award"!
    There was a smile on my face!

    Still plenty of work to do. Electrics, lights, registration....

    Ari Berghäll

    Päätoimittaja/Editor in chief


    PRIMER MAGAZINE

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  29. Ari, congratulations to you. Your perserverence paid off.
     
    Kontra likes this.
  30. j hansen
    Joined: Dec 22, 2012
    Posts: 3,180

    j hansen
    ALLIANCE MEMBER

    Great job.
     
    Kontra likes this.

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