In San Jaun Capistrano loaded for the trip homeoh dear….lawn sculpturethe neighbors are used to itReally?
And this in September 2022
Early morning delivery
And the process:
Construct new chassis
making and check fitting crossmemberscut for rear radiusfinished rear radiusfinished axel cutoutreinforcing plate on axel cutoutreoinforcement platewelding reinforcementreinforced railfinished railsnew front crossmemberfit pedal setset-up and weld crossmembersbend rails with oxy/actcheck square, centered, and no twistweld spring bracketscheck fit springsset-up and drill bumper supportsetch prime inside of crossmemberspaint inside of crossmembersweld crossmember bottom plateslocate and drill shock mounts and angleetch primegray primeThe firewall is a factory new part. Both the firewall and the new chassis are finished in black IMRON
Start putting it all back together:
Rear DampersNew Dual Master CylinderStart fabrication brake plumbingMore chassis parts in ImronFront subframe installed
““““““““““““““““““““““““““““““““““`Make and install the ash gas tank support and install the gas tank. (note: there is more to it than meets the eye. For a complete description see: removing-the-petrol-tank-1950-1967-4-and-44-roadsters in the How I Do It section of the website.)
underside of gas tank platformNew Aluminum gas tank installed
And now we get to replace the kingpins/bushings and install the front suspension; oh joy………
New Kingpins and Bushingscutting old bush with hack saw bladeold bush; note hack saw cut barely goes throughUsing threaded rod to install new bush reaming bush finished kingpin fit
Continue assembling front end
front suspension doneFront suspension doneclean, inspect, repack with new sealsinstall hubs and brake calipersinstall steering bracket and column
NEW factory made body tub
in gray primerin gray primerin gray primernew body now Creamnew body now Cream
Both rear fenders are factory new parts
cowl and new rear fenders in primer drill and fit tail lights more sanding and primingImron on the insideadd a little more creamand a first taste of chocolate
And now for a little engine work:
clean all tapped holesNew Cam BearingsNew Rear Main SealFitting new rear seal with mandrelinspect and recondition oil pumpsoil pump installednew timing chain springnew front sealBottom ends finishedalmost doneAlsmost donefitted to chassisnew high volume oil pumprebuild carbsH6 fittedcarbs installedAll new rocker arms and new shaftnew rockers installedOriginal and new Gear Reduction StarterNew Starter Installed
And some sheet metal bits
new toolbox and battery trayrear valence for two carslayout valencesmaterial cutoutroll beadsbend bottom flangestretch bottom flange to match chassisstretch bottom flange to match chassibasic valence check fit o chassisturn up leading edge flangeturn up top flangenew valence fitted and drilledcheck fit original wing with new valences, bonnet, and cowlfinal fit original wing/new valence on carFinal fit valence to wingnew toolbox, valence, batt tray, in primenew parts in Imronnew toolbox in Imron
Assemble Stuff
firewall and body permanent rear seat check fitsometimes you must call in the professionalsHi-density marine mahogany floors installedrear seatbelts installedFinished floors and other detailsOriginal Moss gearbox rebuilt by Quantum Mechanics with parts that were replacedproper matting installednew toolbox and battery tray permanentnew wing valences permanentNew Welting and Right fender installedRight Fender installedNew taillight installedLeft Fender installedLeft Fender installedchanged black seatbelts for new brown units
Detail Stuff…
install door dovetailsrecondition wiper motors and gearheadswiper motor installed with new mounting kit and refurbished wheel boxesnew rear valence installed with additional running lightsnew battery and stainless hold-down, new fuse box, new horn installed. also Arizona Title Number Plate and heater Caution plate.New Luggage Rack installed and new dual-filament bullet lights, new license plate lightOriginal Heater dissembled, checked and InstalledHeater InstalledOne-Shot oiler tubing completeOne-Shot oiler tubing completefly-cutting dashplate holesengine turning dashplatedashplate with instrumentsNew Morgan ScriptNew 13″ Auxiliary Fan5 New Tires DeliveredNew tires and tubes mounted on original wheelsAll Stainless Steel muffler/exhaust systemNew TreadstripsNew air baffle for radiatorBaffle installed (necessary? probably not but it can’t hurt)Grill installedfabricate and install stainless steel radiator stay rodsfabricate stainless steel bracket for center brake lightbracket with wire tube completerear wire harness and center brake light installed Completed wire harness installed. left headlight and directional installedall exterior lighting complete (except fog/driving lights)new wing lightswing lights completebegin interior panelsretractable shoulder belt installed and much of right side interior finishedleft side trim in workdaughter Robin (recruited for sewing skills) laying out hidem gimpsewing hidemcarpet underlayment fittedFront carpets fitted prior to bindingRear carpeting fitted prior to bindingmaking transmission tunnel cover over formmaking transmission tunnel cover over formAh, the concenttration: Shayna sewing the tunnel coverfabricating the stainless threshold platesfabricating the stainless steel badge barfabricating badge bar bracketsbumper supports with welded fog light bracketscheck fitfog and driving lights permanentfabricating the stainless threshold platesthreshold plates completed and Installed
And now the Wings … and Bonnets
Sandblast interior (many old sins reveled)once there was a small repair neededa patch was brazed over whole arearemoving patch exposes large area rusted. now a big repair is neededRusted area cut out, new patch fittednew patch hammer welded in before adding lead to finishOuter surfaces with repairs completed; ground ready for etchetch prime inside and outPrimer/Surfacer first passprime, sand, fill, sand, prime, repeat70+hours of prep work later: black Imron on inside surfacesand then brownand now there are two…Wings partially installedCowl installed loose waiting for bonnet fitBefore there was Cream then bright red (and dark red and gray, or brown, and green!)Primer Surfacer prior to wet sandingthe End of Painting (I hope)Turning bar stock to make oversize hollow rivetsLast turning operationFinished RivetsBonnet latches riveted and assemedThreading Stainless Steel rod for bonnet staysLatch modified for Bonnet StaysBonnet Stays installed
Revise Seats
saggy springs are us…new seat springing in workcounterboring track support blocksAsh support blocks assembled with threaded rodfour sets of tracks mounted on support blocks finished reinforced and sprung passenger seat on slides.new covering on driveshaft tunnel, seat belt anchors fitted, passenger seat fitted.driver’s seat fitted
Interior Woodwork
From mighty Caro Walnut trees…old dash and 2 1/2″walnut blank (resawn to make three) dashJig saw at angle to cut glove box door at a taper doorfinished door does not drop through (0 kerf)through, )Do little dashboards growinstruments fitted ready for finishinlaid door trim panels and walnut steering wheel center.spray-sand-spray-sand-spray
The Hood (“top” to the colonials)
Original hood check fitOriginal hood used for patternsShayna putting it all togetherPatterns laid out and cut from Haartz “Stayfast” fabricCheck fit hood in work.Check fit hood in work.layout rear windows
