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1959 356A S/R coupe project chassis # 108625

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  • JTR70
    replied
    Rear wall repairs in basic completion:
    Click image for larger version  Name:	IMG_0177.jpg Views:	0 Size:	248.6 KB ID:	113966 Final trimming complete and tacking in from the flanged sides first. I normally like to begin from the center outward but it was more critical that corners and flanged edge continued the line from the original panel.
    Click image for larger version  Name:	IMG_0178.jpg Views:	0 Size:	225.8 KB ID:	113967 Once the sides where set then the rest of the run was tacked together.
    Click image for larger version  Name:	IMG_0181.jpg Views:	0 Size:	221.2 KB ID:	113968 All stitched up with most of the weld seam grounded back. Have yet to finish up the corners but that can be done anytime before the walls final installation.
    Click image for larger version  Name:	IMG_0188.jpg Views:	0 Size:	232.5 KB ID:	113969 Now that I have a basic wall I wanted to begin locating it into its final centered and level position in between the side walls of the battery box.
    Click image for larger version  Name:	IMG_0189.jpg Views:	0 Size:	241.2 KB ID:	113970 This walls initial location was sight marked and measured off of the beam and the footprint of this car's original walls attachment point on the left side. This was only a jumping off point however. Every component comprising this final frame structure is now either new reproduction, crash repaired, rust repaired or both individually so with that reality in mind it is safe to say there will be many, many fine adjustments and changes that will be needed during the pre-assembly process to get all of these panels to fit tight and square in relation to one another when its all over.
    Last edited by JTR70; 04-24-2023, 04:36 AM.

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  • JTR70
    replied
    Thanks Roy! I agree with you, I can remember seeing reupholstered dashes that looked like over stuffed pillows from my own beginnings and thinking how terrible it all looked in there. The leading edge of the top had a formed fibrous lip that created that nice radiused turn your describing; then a thin padded overlay.
    Click image for larger version  Name:	IMG_0185.jpg Views:	0 Size:	184.6 KB ID:	113962 My father and I recovered this dash way back in the late '80's. We used a thin high density foam for the top overlay and it was a must in my eyes that the overall profile shape run as flat and firm as possible.
    Click image for larger version  Name:	IMG_0184.jpg Views:	0 Size:	513.4 KB ID:	113963 The original coconut strand formed leading edge was of course crispy and unusable so thick blocks of foam where glued to the leading edge and once set the foam was sand-shaped to contour of that old lip. The final shape and presentation under the Naugahyde turned out just like I had hoped and this old repair/restoration is actually the only feature remaining from the 80's that I still agree with and feel is nice enough to not require a redo except for the actual covering itself. It needs to be recovered in the correct German style grain.
    Click image for larger version  Name:	IMG_0187.jpg Views:	0 Size:	228.0 KB ID:	113964 The dash top for this project is now epoxy and top coated completing the prep on this end. Its now off to A.I. for reupholstering. Back to the battery box.

    Justin
    Last edited by JTR70; 04-23-2023, 06:47 PM.

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  • roy mawbey
    replied
    Justin what an interesting two pages of forum read. There is just so much metal to get right. Your effort here in the dash top work I have never seen so well detailed before, I have often looked at my original dash and wondered how it was put together now I know. I am aware my original factory vinyl dash top is padded in a way where the top vinyl surface is actually flat until it has the radius to meet the insturment face. I have seen some cars with too much padding on top and too soft. The work you are doing just looks so correct, well done !

    Roy

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  • JTR70
    replied
    Click image for larger version  Name:	IMG_9803.jpg Views:	0 Size:	208.1 KB ID:	113955 Lateral repair flange sections complete; Recycling a little more of the old metal to make them. These pieces where made a while back then set aside while I went back to the beam pulling duties.
    Click image for larger version  Name:	IMG_0154.jpg Views:	0 Size:	232.9 KB ID:	113956 Fast forward and these corners are now tacked in. Lateral flange sections also tacked. Repurposing more scrap metal.
    Click image for larger version  Name:	IMG_0155.jpg Views:	0 Size:	237.1 KB ID:	113957 Final trimming and fitment of the main repair section soon.
    Click image for larger version  Name:	IMG_0166.jpg Views:	0 Size:	210.9 KB ID:	113958 But I had to add one more profile shape in first. There is pleat with a slight kick in the bottom flange along both sides. Over exaggerated bend while installing this detail here.
    Click image for larger version  Name:	IMG_0167.jpg Views:	0 Size:	653.3 KB ID:	113959 Relaxed back out and now just about ready to begin tacking this repair section in.

    Thanks for looking!

    Justin
    Last edited by JTR70; 04-18-2023, 10:42 PM.

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  • JTR70
    replied
    T2 rear battery wall repairs continued:
    Click image for larger version  Name:	IMG_9723.jpg Views:	0 Size:	213.7 KB ID:	113949 New lower wall section flanged and ready to take on the rest of the needed shape.
    Click image for larger version  Name:	IMG_9724.jpg Views:	0 Size:	219.1 KB ID:	113950 The bends for the recess are a much softer and larger roll; not a simple 90 degree bend. Had to scrounge and find suitable die and fortunately I had this heavy stock with just the right corners on it.
    Click image for larger version  Name:	IMG_9725.jpg Views:	0 Size:	196.7 KB ID:	113951
    Making the perfect hammer form.
    Click image for larger version  Name:	IMG_9727.jpg Views:	0 Size:	239.6 KB ID:	113952 Basic lower repair section shaped.
    Click image for larger version  Name:	IMG_9778.jpg Views:	0 Size:	186.2 KB ID:	113953 Then it was onto the lateral overlapping corners.


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  • JTR70
    replied
    Dash part 4:
    Click image for larger version  Name:	IMG_0126.jpg Views:	0 Size:	198.8 KB ID:	113942 Final shaping and trimming. Right side completed.
    Click image for larger version  Name:	IMG_0128.jpg Views:	3 Size:	200.2 KB ID:	113943 A bit more cutting and welding on this side to get it to lay right.
    Click image for larger version  Name:	IMG_0132.jpg Views:	0 Size:	192.5 KB ID:	113945
    Edge reveal just above the gauge was trimmed back a touch too far and straight as delivered so a sliver fill was added to clean up its shape. Only a whisper of it remained after final shaping but the final presentation will be far nicer once its wrapped in leather and up against the profile shape of the dash face.
    Click image for larger version  Name:	IMG_0133.jpg Views:	0 Size:	462.7 KB ID:	113946 Installed for one last time. Fully trimmed, fitted and set screwed into final position.
    Click image for larger version  Name:	IMG_0134.jpg Views:	0 Size:	459.7 KB ID:	113947 Hitting it with a quick top coat of sealer and paint next then off to the upholsterer it goes. Back to battery box repairs.

    Thanks for looking!

    Justin
    Last edited by JTR70; 04-16-2023, 11:06 PM.

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  • JTR70
    replied
    Dash top part 3:
    Click image for larger version  Name:	IMG_0112.jpg Views:	0 Size:	150.4 KB ID:	113936 Onto the left corner. As well as drain hole duties the lower corner on this side came with a weird contour shape that will need some correction.
    Click image for larger version  Name:	IMG_0121.jpg Views:	0 Size:	175.3 KB ID:	113937 Will need some relief cutting and bit more welding on this side.
    Click image for larger version  Name:	IMG_0122.jpg Views:	0 Size:	155.1 KB ID:	113938 Began relief cutting and reshaping that corner but before I I went any further now was the time to dial in the mounting screw holes to lock in its final mounted position. Paper tabs locate the original holes then flip out of the way for another dash top mock up.
    Click image for larger version  Name:	IMG_0123.jpg Views:	0 Size:	168.1 KB ID:	113939 Then lay over top showing me exactly where to drill. Recontouring that corner was well in process.
    Click image for larger version

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ID:	113940 Process repeated on the right side with mounting screws installed here. With this now set fine contour trimming of its edge to more closely follow the dash reveal shape.
    Last edited by JTR70; 04-16-2023, 10:40 PM.

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  • JTR70
    replied
    Dash top part2:
    Click image for larger version  Name:	IMG_0110.jpg Views:	0 Size:	187.9 KB ID:	113930 With the dash top fully seated I moved to the right side corner first to shape and relief cut an opening for the sun roof drain tubes.
    Click image for larger version  Name:	IMG_0115.jpg Views:	0 Size:	180.6 KB ID:	113931 Unfortunately I don't have an original reference as to how these corners were trimmed back so it will be opened slightly larger than the drain hole behind it.
    Click image for larger version  Name:	IMG_0117.jpg Views:	3 Size:	168.1 KB ID:	113932 Final opening shape with rolled edges to make life easier on the eventual material that will be wrapped over top.
    Click image for larger version  Name:	IMG_0118.jpg Views:	3 Size:	176.2 KB ID:	113933 Another of many repeated test fits as it goes. Slightly oversized to account for future material thickness.
    Click image for larger version  Name:	IMG_0119.jpg Views:	3 Size:	165.3 KB ID:	113934 I don't have a section of actual drain tube on hand either so this is all just a guesstimation. Hopely this will work on installation day.

    Last edited by JTR70; 04-16-2023, 10:10 PM.

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  • JTR70
    replied
    Dash top detour:

    Upholstery for this car is getting ready to wrap up so I need to get this new dash top fitted and trimmed to this car and sent off to Autos International.
    Click image for larger version  Name:	IMG_0105.jpg Views:	3 Size:	185.7 KB ID:	113924 This R/D's dash top offering and I have to say, right out of the box , this is the best fitting new part I've ever tried. Its a complex piece for sure and the initial fitment issue was its inability to slide all the way home. As you can see its leading edge was about a half inch shy of the car's leading edge reveal.
    Click image for larger version  Name:	IMG_0108.jpg Views:	3 Size:	192.5 KB ID:	113925 My first thought was that the tabs were set just a few mm's too far forward.
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ID:	113926 I thought I'd have to remove them for repositioning but after lifting them upward...
    Click image for larger version

Name:	IMG_0109.jpg
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ID:	113927 that turned the trick allowing the cap to move forward that last half inch. Sure is nice when the answer is easy. Doesn't happen too often but I'll take it when I can.
    Click image for larger version

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ID:	113928 Fortunate to have my original dash top on hand for correct positioning and contour confirmation.
    Last edited by JTR70; 04-16-2023, 09:53 PM.

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  • JTR70
    replied
    Back to upper vertical wall repairs.
    Click image for larger version  Name:	IMG_0100.jpg Views:	0 Size:	233.2 KB ID:	113902 Cleaning off the remains of the old trunk floor on the lateral flanges and straightening out some old accident damage.
    Click image for larger version  Name:	IMG_0101.jpg Views:	0 Size:	218.6 KB ID:	113903 Lateral top flanges cleaned and prepped. Reopening and flaring the center conduit hole next.
    Click image for larger version  Name:	IMG_0103.jpg Views:	0 Size:	227.3 KB ID:	113905 The hole was flared towards the tube end as originally done.
    Click image for larger version  Name:	IMG_0102.jpg Views:	0 Size:	219.1 KB ID:	113904 A gas weld around the tubes end on this side will join these two when the time comes.
    Click image for larger version  Name:	IMG_0104.jpg Views:	0 Size:	231.3 KB ID:	113906 Repairs and prep between these two panels mating surfaces all but complete. Onto repairing the bottom and the sides of this wall so it can finally go in for good.

    Thanks for looking!

    Justin
    Last edited by JTR70; 04-04-2023, 05:46 PM.

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  • JTR70
    replied
    Forward trunk floor repairs complete:
    Click image for larger version  Name:	IMG_0093.jpg Views:	0 Size:	212.6 KB ID:	113896 Entire run stitched together.
    Click image for larger version  Name:	IMG_0091.jpg Views:	0 Size:	245.2 KB ID:	113897 Lots of grinding and weld finishing next; especially around that ID number. Heat deformation and a few low spots of old accident damage under these two reinforcement ribs so they were removed for a clear shot with a hammer and dolly.
    Click image for larger version  Name:	IMG_0094.jpg Views:	0 Size:	232.0 KB ID:	113900 Weld joint smoothing complete with low spots and deformation leveled. Lateral plug weld holes drilled and as numerous as the original spots to replicate the attachment strength.
    Click image for larger version  Name:	IMG_0097.jpg Views:	0 Size:	224.8 KB ID:	113898 With the holes predrilled I could begin heeling the flange over a little more in preparation for the vertical wall flange.
    Click image for larger version  Name:	IMG_0099.jpg Views:	0 Size:	212.5 KB ID:	113899 Weld repairs to the floor all but complete. Onto the vertical wall repairs.
    Last edited by JTR70; 04-04-2023, 05:30 PM.

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  • JTR70
    commented on 's reply
    Hi John, Unfortunately I don't own that fancy pulling arm but it wouldn't have helped much for pulling out that old battery wall since most the deformation/damage was lateral. Definitely, I do try and save as much of the old metal as possible where it makes sense but some times it isn't worth the effort and you're just better off with a fresh piece of metal. Just doing the best that I can to copy what the factory did all those years ago with what I have on hand and my current skill level. Thank you very much for those kind words and wishes!
    Last edited by JTR70; 04-03-2023, 09:22 PM.

  • JTR70
    commented on 's reply
    Thanks Roy! I have a corner of junk/scrap metal that I'd like to get rid of but can't bring myself to just throw it out and its instances like this one that really reinforces why I don't. It was nice win/win though as it saved some fabrication time, repurposed an old part and reduced my scrap pile just a touch. Agree, rebuilding these cars in the way that they were originally constructed especially down in the deep recesses can be extremely trying and corner cutting can become a very attractive option when you get really deep into things. I've been there many a time...
    Last edited by JTR70; 04-03-2023, 09:08 PM.

  • jjeffries
    replied
    Hello Justin (and Roy), What lovely work as always. Reading it/catching up, I was anticipating that you’d straighten that damaged driver side vertical panel with a wide clamp and a Celette pulling arm, plus some heat and hammer/dolly work. Obviously not necessary. You do conservation as much as restoration, utterly scrupulous and almost monk-like in your integrity … a lesson for us all. I certainly always come away from reading your posts with a healthy dose of Zen.

    kind wishes, John

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  • roy mawbey
    replied
    Justin if ever the there was a case for using a spare part that was it! Again so sensible and rewarding to see just how good that area will be. More and more it kakes me wonder just how many people can start a project and find they can never finish it. With careful thought and some luck in having spare parts or at least another car to compare against it must be so hard to complete things. Even harderwhen a repro part that really looks so good has the dimensions too short in places. Many would think just weld it in, add some pieces and it will all fit together just fine! Again without the right inspection fixtures etc so very difficult.
    Roy

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