1958 +4_4str_3585 – Mad About Morgans

Before the “incident”.

The restoration: chassis

route s/s brake lines to dual circuit master

Restoration: odds-n-ends repairs

restoration: reassembly

differential, springs and dampers installed

grind and generally clean-up the bellhousing casting

original paint on steering column did not look so good when installed.

priming steering column. (not in original plan for paint)

steering column painted in situ (afterthought)

Fabricating firewall

beginning fixture by modifying one from DHC firewall

fixture complete with old firewall in place

welded sides with top flange for hem formed

Hem partially formed, test fitting toolbox

drilled holes and cutouts with parts test fitted

Fabricating Wheel Arches

routing stacked panels using original as template

camp new and old together to verify cut locations

make new shoes for baby…………….

rip and dado for plywood wheel arch panel

Use dado to cut relief for fender flange

finished part with cut for lower rear stringer and screws into wheel arch panel

“shoes” installed with thickened epoxy to make water seal

strip, clean repair and Ospho seat frames and rear panel

continue with wood framing:

Aluminum angle clamped to inner panel to support routing fixture

Make new connecting blocks (attachment for hood bows, two cars). Fussy little part that is usually split and rotted. Order of operations: Route curved rabbet to match wheel arch. Table saw straight edges. Band saw (thin blade) curve to match hood bracket. Route rectangular recess for the elbow rail.

orient pattern on stock, note grain direction

make pattern and dress smooth by sandpapering on wheel arch

routing pattern clamped to stock, rabbet complete

multiple rabbets on stock for four parts

nail part to parallel sided scrap to safely cut short rips.

check fit and mark block location on wheel arch

pattern clamped in place to route mortise for block. Opening in bottom of slot is starting location for router.

you don’t have to be a hippy to appreciate a good joint

Anything you don’t explicitly make fit, won’t fit. Verifying that things fit and making corrections as you go exponentially increases the time it takes to complete anything. However; when you are done the odds are greater, (not absolute but greater) that the result is correct.

Hood Bows Check fitting indicates that the bows are badly out of shape.

multiple bends prevent bows from nesting

transition blocks dressed to match hood frame brackets

bows nested after straightening and repairs

bows erected after straightening and repairs

Fit and repair Spring Covers. The driver’s side spring cover was “modified” by a previous owner and needs to be rebuilt. Also, the factory left the inboard end of the covers open but I prefer them closed.

finished covers with forward ends welded closed

Check fit Cowl and Bonnets prior to finalizing the location and structure of the scuttle wood.

Continue making and fitting wood parts.

NOTE: I usually make patterns; the rest of the time I make scrap.

Dress stock. 8 qtr shown, 10 qtr would be better.

determine angle the firewall wood leans in

rip angle on edge that attaches to the sill

rough bandsaw two pieces from wide stock

compound set to firewall angle, blade tilt set to cross angle.

check fit rocker: sill to firewall wood.

bandsaw and check fit sweep of wing under rocker

Test fit and install more stuff

top angle cuts on stock for two door hinge posts

two sets of hinge posts ready for bottom rabbet.

Rats; It is easy to convince yourself that something is “good enough” even though it isn’t. After all the wood framing was done I decided the pieces at the front that attach to the firewall needed to be replaced.

comparing the new parts to the originals

Sheet metal

I did not take many pictures of 3585 sheet metal in-process. It was done simultaneous with 5674 and is fairly well shown in that section of the web-site.