1959 356A S/R coupe project chassis # 108625

[JTR70]

Thanks a lot Scott! yes, it is a Trevor's nose and I am not surprised that there was a discrepancy or two when you began fitting yours. They are hand made so modifications to get them to fit right on a specific car is a given. I'd be more shocked if it slipped right into place out of the box....Something must be wrong here...

[roy mawbey]

Justin, some time since i posted a reply. Not intentional just occupied with some health issues which seem now to be working out okay so far. Your recent wok getting those gaps so nice to look at is amazing. So good to look at Justin. I did a fair amount of leading year years ago and I remember the fact I was so pleased with the results which have lasted over 45 years and never shrunk or moved. The results you are getting are really good and a good idea to have fitted the rubber hood seal and engaged the bonnet lock too.

Keep up this super work !

Roy

[Scott B]

Justin this coming along nicely. It’s tough pulling it all together. You are within striking distance. Is this a Trevor Hammerworks nose? I found the crown on the drivers fender by the headlight was high by about 3/8ths.

[JTR70]

Finishing up the correction around this right side turn.
After a few passes I had enough solder applied then it was back onto shape filing.
By sessions end I had a decent roughed in gap that I could work with and refine further. Most importantly those troublesome shoulders now flow off the edge of the hood. Latched with seal installed.
As the leadwork progressed I jumped to the back corner to continue stitching this cut line back together. I had to exercise extreme patience through here and hold the welding to only a quick tack weld as I jumped to the opposite side while the previous area cooled. I really wanted to just lay down a bead and get it done but I had to keep heat warpage to a minimum. I have access to the back to work and planish this joint which is why this line was chosen but its limited access so I couldn't get crazy.
It paid off in the end with minimal warpage across this joint. Repeating on the right side soon.
Ready to go back and finish up the bumper modifications and final fitment to the car.

Thanks for looking.

Justin

[JTR70]

Finishing up those lost lines.
High spot of this shoulder tapped back level and in contour with the hoods edge. Cleaned and ready for a finishing coat of solder.
Soldered up the side and file shaving and shaping for a 3mm+ gap.
Basic gap with some room left for further improvement. What's most important here; I've got a latched hood with seal creating a level transition from the edge of the hood onto the body.
Repeating the same process on the right side. Fender side tapped down and the edge of the hood tapped upward where needed to meet in the middle somewhere.
Once it was close then it was onto paddling on the lead solder. In process here.

Thanks for looking.

Justin

[JTR70]

Took a little break from filing and shaping lead and went back to stitching in this long weld joint.
Back to hood fitment with a small adjustment needed. I ended up turning the plunger in a little more for a tighter latched position to engage the rubber seal a little more. Once I reset that and opened up the leaded gap back to 3mm+ to accommodate this change I lost my matched contour elevation with the fender in through this area.
Same issue over on the right side though this side of the hoods leading edge needs a little tapping upward so not as bad as it appears here.
Wasn't sure how I was going to get this area back in line. First thought was to cut the vertical flange in through the high area there then tap down and reweld. Later figured the best approach was to heat the base of the vertical flange then tap the high spot downward. This did two things, it saved more cutting and rewelding ceremony and this approach tightened up the gap slightly as the flange was heated and heeled over. In process of that here and was working as planned.
Heated, carefully tapped then checked and rechecked with the edge of the latched hood (with seal) as it went. Much improved in this shot with just a little ways more to go.

Thanks for looking.

Justin

[JTR70]

Opening and shaping the gap. Testing seal engagement against the hood with a piece of paper as a feeler gauge. As it went the hood needed to close down a little tighter so the gap had to be opened up a touch more to compensate as this went.
Initial 3mm+ gap getting real close. I worked my way from center on up over to the left side first.
That really troublesome continuation contour from the hood onto the nose was finally headed in the right direction.
Other than the shape the other critical detail was that the edge of this hood remains thin.
Making my way around the left side first to continue opening and shaping the final gap against this hoods edge.

Thanks for looking.

Justin

[JTR70]

First pass of lead solder and initial filing. Ready to begin carving out and shaping the gap.
I'll need the seal installed to dial in the gaps correctly.
Old trusty hole puncher has a nice small diameter die perfect for those little screws. Punching the hole is far easier on the seal than just forcing the screw through it. I've torn few seals that way.
Begin drilling the holes for the seal and positioned based on my original reference car.
Made the joint will end up being positioned between the lower two screws of the right side corner clamp.

Dialing in the gaps with the added tension of the rubber seal next.

Thanks for looking.

Justin

[JTR70]

Wrapping up the hood alteration:
Flange detail added separately. This shape was far too complex for me to add that in one piece cleanly.
One of several test fits as the welding progressed to make sure it was maintaining the new shape I needed.
All stitched back together and just cleaning up the last of the weld runs.

Reshaping detour completed.
Remounted for another test fit. Ready for skim coat of solder to get that last 5% of the flaws out.

Thanks for looking.

[JTR70]

Hood re assembly:
New section all stitched in.
Slightest pressure brings the new edge and general contour of the hood out into a much better profile shape with the new nose.
Tried to avoid it but to work this weld joint and section into the needed shape I had to have access to the back side. Removed just enough subframe to allow a clean shot at it.
Ready to add it back in but had to take out a little residual crash damage out first.
Tacked back in and slowly stitching it back together.

Thanks for looking.

Justin

[JTR70]

The end of the hood is that domed shape which is pretty rigid and doesn't really lend itself to relaxing much. I could beat the leading edge upward where its needed but everything behind it wasn't moving. The arch marked out in blue highlights the entire area that drops too quickly and needed to come and outward a few more MM's. After a lot of debate I finally settled on cutting out the smallest arch that I could then relief cutting the center and spooning out the rest of that tight area.
On a positive note I am getting rid of a very thin and heavily pitted section on both sides with a fresh piece.
Hammering the new section into the needed domed shape.
One of many tests as the needed shape progressed.
The rest of the area was pulled and tacked to help hold the needed new contour. Its a touch shy here but well within striking distance. A lot variables still come was the reassembly and welding phase begins. I found myself wishing I would have caught this while I had the hood apart but hindsight being what it is I would have never known this was an issue until the nose and hood were set in their final assembled and best adjusted position. A real catch 22. Reassembly next.

Thanks for looking.

Justin

[JTR70]

Needed a little break from the front bumper.
So I went back to lead soldering the leading edge of the nose for final contour shape and eventual hood gap.
I haven't done this for a while so it took a minute to get my feel back as to how much heat to throw at it without having it run off onto the floor as I added and shaped it. By these runs I was in the middle of figuring it out again.
After several rounds of solder and file shaping I had a good shoulder built up that softened and carried the new noses profile into the hood.
The problem I was running into now was the hood's profile towards the edge tucked under too quickly giving it an underbite. This would prove to be a little tricker to correct than I first thought. Couldn't shave the leaded edge back to the hood as the contour and transition would be completely wrong as both sides would be subducting as they met creating puckered effect. The edge of the hood had to be relaxed and brought outward. It would require a little cutting on the hood side to get these two panels to flow out smoothly together some where in the middle.

That up next..

Thanks for looking!

Justin

[JTR70]

Thanks Roy!!

[JTR70]

Thanks Scott! I was just shooting for a match to my factory original example as closely as I could.

[roy mawbey]

Yes Scott I agree with you he has transformed the front so well. Amazing bit of work to make it for me perfect.
Well done Justin indeed.

Roy