1959 356A S/R coupe project chassis # 108625

[JTR70]

Continue dialing in the final bumper fitment:
Bumper brackets are fully synched up at this point. I have about an inch gap at the end on the right side here
but a non existent gap on the left side. The problem now is that the bolts are bottomed out in the bracket slots and won't allow for any additional movement to the left.
The right side is maxed out but at this point I'm still in need of an additional 1/2 inch of adjustment. I could open the slots up further but the bracket half on the left here would out of range. As you can the base mount has been damaged and rewelded at some point so one thought is to cut it free and move it over where it is needed for this specific application.
On the left side only the inner half of the bracket is bottomed out but the outer half has ample for further adjustment. Again not sure if I'll move and reset the base mount or modify the brackets.
Before I commit to changing anything I wanted to establish a base contoured fitment with the new nose and this old original bumper. Bumper was stripped entirely and was now in process of dialing in a uniform reveal/gap between these two parts. More on this next.

Thanks for looking!

Justin

[JTR70]

front bumper fitment to this car:
Bumper is now resting on wood pegs so I can "float" it into its best adjusted position with the new nose. It needed to come in a touch closer for about a 2 inch reveal or spacing away from the body. By the time I achieved that the tip of bumper closed down to nothing.
Pretty much the same issue on this side though the radius shape on this side isn't quite as tight and the tip begins to swing out.
I'm using this original nose and bumper as my guide. The general distance through the center is just shy of 2 inches with a livable but slightly tighter spacing as it makes the turn towards the tip.
The mock ups are telling me that the general overall contour of this bumper is a touch too tight; at least for this newly established nose. The center of this bumper has been rewelded at some point and I detect residual crash damage through its center. Knowing that its not pristine stock makes contour adjustment changes much easier.
Began by relief cutting it through the weld joint to begin relaxing and opening up its shape. This quick cut immediately allowed the bumper to come in closer and bottom out against the skin at the center; extreme but just working back from there. While it was heading in the right direction, swinging it opening this way was now flattening its profile shape a bit too much at its center. It was taking on a bit of reproduction look so I needed another approach to get the clearance and final contour shape I was looking for.

[JTR70]

Front bumper fitment continued:
Eventually came to the conclusion that it would be much simpler to continue the cut and fit each side individually to the body.
Cleaning up the edges so the halves can be retacked in their newly needed position. Bodywork was done previously by someone with a very acceptable thickness of filler.
This approach immediately turned the trick for this left side and closely resembles my original reference reveal in both width and contour shape.
Was able to get a similar shape and width on the right side but it begins to sweep away from the skin starting just after that mounting hole.
Direct comparison laid over top highlights that this shape discrepancy. Confirmation that this issue is with the bumper and not on the body. Will be tightening up this bend as the fitment continues.

Thanks for looking.

Justin

[roy mawbey]

Justin yesterday I took the measurement of the bumper tips to the right and left fender. The gap was equal at 3/4 of an inch ( 19mm ) I was surprised they were so equal its not an easy job to get those gaps correct you are winning with that. So many difficult decisions to get this result. Not that many would have attempted your way round this. So many things to think of Justin.

Roy

[JTR70]

Hi Roy, Thanks! Definitely a process to get all of these components both old and brand new to fit and work together like they need to but its steadily getting there. Thank you for that confirmation info on your car. Justin

[JTR70]

Bumper halves going back together:
After several rounds of mock up with the nose an additional 3MM width was added in along with the slightly more relaxed profile to give both the reveal and spacing from the nose I was looking for.
Began backfilling and tack welding from the middle so I could still adjust the overall profile shape of the bumper as it went back together. Once the edges were welded the final shape was locked in.
There is the reveal spacing and shape against the nose I was looking for.
Got the right side spaced to match the left but again I lose the line as it relaxes and sweeps too wide just after the mounting hole for the overrider tube.
Now I could begin relief cutting to tighten up this turn. Initially tacked and on for another test fit before I commit to more welding. The bumper was slid over tight for this shot so I could get a better feel for the shape match. Getting closer.

Thanks for looking.
Justin

[roy mawbey]

Well done Justin a good method of getting the bumper alignment correct. Again I have to say relief cutting was never in my head to make corrections until you started this restoration. I will never forget the process now !!

There is so much involved in body restoration so that it looks really correct.

Great bit of work !

Roy

[JTR70]

Thanks once again Roy! It is a process that keeps on repeating itself doesn't it? You just can't realistically expect these pieces to just fall into place. Everything needs at least some adjustment to fit or flow together properly and some a lot more than others as you have well noted.

[JTR70]

Begin refitment of the bumper trim.
Completed the shape adjustments to the front bumper to match up with the new nose as closely as my original reference is showing. Onto refitting the bumper trim to its slight changes.
Began with the uprights since their position remains fixed. Then the tube was slipped in afterward.
That 3mm of additional width in the overall relaxed arch did throw of the needed hole position out at the tips of the tube off.
The holes on both side had to be moved inward about the holes width. Will backfill this once everything is fitted and set for the final time.
All bumper trim fully mocked up and bolted down. Making the needed changes to bumper iron mounts themselves next to allow a shift to the left that was needed from the beginning.

Thanks for looking.

Justin

[Scott B]

Nice elegant long smooth taper between body and bumper to outside tip. Huge difference. Looks so comfortable and matted.

[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

[JTR70]

Thanks Roy!!

[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]

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]

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]

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]

First pass of led 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