1959 356A S/R coupe project chassis # 108625

[JTR70]

Best place to make the changes:
Tube mounted directly to the upright as starting point.
Not only too long now but swings very high and wide with the other end just about where it needs to be.
Everything to in the inside of the guard is stock so this end of the tube would be established first. This 90 degree bend really dictates the uprights orientation. If its not just so the end of the tube would not reach the surface of the bumper. So as you assemble, they tell you exactly where they need to be in relation to one another. The cut and following changes would be made just to the outside of the bumperette mounting hole. With the tube cut I'll not only shorten it but I also be able to index it slightly for a flush fit to the bumper.
This bumper was a Euro-version so it was a clean slate as far as the tube mounting holes went. To locate the hole in just the right spot this temple was taped to the tube end and once I had the tube exactly where I wanted it was peeled free from the tube and simultaneously taped to the bumper. Ready to confidently drill the hole.
Inside of the tube bolted up snug for the first time. So far so good. You can see by this point the bumper mounting bracket has been welding back in for good. Cutting and modifying the bumper through the exhaust arches was the best place to make the changes as this bracket only conceals the weld joint but also reinforces it. Cutting the tube the in half next.

Thanks for looking.

Justin

[JTR70]

Getting ready to make the first cut.
Before cutting the bar it was slid inward by that one inch that was removed out of the bumper to establish where the tip of this tube needs to end up to fit and look correct.
Same paper template procedure to locate the mounting hole as was done on the inside. By this time all the original deco holes were welded closed as they needed a reset as well.
Commitment time. As planned the weld joint will be to the outside of the original upright mounting hole.
Both ends of the tube mounted onto the bumper highlighting how much needs to come out...about an inch.
That one inch section removed here but it won't go into the trash. Its being repurposed as reinforcement sleeve across the final weld joint. In the process of removing width out of it here so it will snuggly fit into the I.D. of the tube halves.

Thanks for looking.
Justin

[JTR70]

Right tube welded back together:
Tube mock ups began. Fully bolted down snug with the outer section indexed slightly for a smooth transition across this joint and a flush fit against the bumper out at the tip. My weld joint ended up being twice as wide as I had wanted. I was looking for a 4mm gap for a root pass with a good remaining weld shoulder left once it was all dressed even smooth for replating. I mistakenly made the final cut on the wrong side of my marker line creating too large of a weld joint.
A bit too wide to back fill with weld so I cut a quick filler ring. Two welds instead of one but I was just relieved that this mistake wasn't too serious.
Tack welded to hold the final needed shape.
Dismounted one more time so I could Zip it all together.
Shoulder at the contact point ground down quickly as I was anxious for a confirmation fit. Bolted right back up where it was before welding with a snug fit inside the bumperette recesses. So far so good.

Thanks for looking.

Justin

[JTR70]

Right side overrider bar modification:
Bar shape remains smooth and still fits against the back drop of the tail panel itself. Once its rechromed the alteration will be completely undetectable a big relief, especially after cutting up original parts.
End of the tube terminates right where it would in relation to the deco and the tip of the bumper before both these parts were tightened and shortened.
Contour looking down the assembly will look stock and appear unchanged as well.
Bar fits tight into the guard as well as the bumper without being forced into position. Making everything fit together with minimal tension was top of the list.
After that confirmation fit the bar was removed and the rest of the weld joint was ground smooth and semi-polished in preparation for rechroming.

Thanks for looking.

Justin

[JTR70]

Refitting the deco trim:
Couldn't get past some of the weld shoulder out here.
but its close enough to leave for the chrome shop to fill with either solder or copper.
Right side bar complete. Onto the left side but first,
I wanted to fit the new deco strip in first.
I filled in all the original deco holes freeing it up to be mounted directly at center with the uprights recess openings. This way there is no alignment issues or a forced fit when it all goes together for the final time.

[roy mawbey]

Justin do you know after looking at all that effort regarding the above deco bars I am actually quite pleased I have a Euro version car that does not have them! You have done well to sort that all out.
Of course having those could save you so much if the rear end of the car is hit!
Roy