Coupe into Speedster Conversion

[John Pierce]

Justin,
That turned out real nice! I really like the picture of the tree of clamps....no movement there.

JP

[JTR70]

Thank you John! Had to make sure it didn't move during the install. As you know if it can go wrong it will if you don't watch it.

7/27/14

Right side A-pillar closing panel and pocket fabrication.

left template flipped over for a right side pattern and basic shape cut from steel here. As with the previous repairs the luxury of flipping an existing template over for the opposite side saves a bit of time. Duplicating the procedure also helps things along too.

Initial bends in at the base and along the seal channel making this first test fit possible. Good so far.

Today's accomplishment of a new closing panel and an initially shaped pocket. Continuing on tomorrow. Thanks for looking! Justin

[Drew.s]

Great work Justin.
Thanks for the close up detail pics of your door tops, I'm assuming the pins stand proud and float so that the vinyl covering can be pushed underneath?

Your A pillars are looking superb, before you throw your cardboard template away could you take some measurements for me.

I have drawn out what I think you have been making but would love your accurate measurments, please feel free to amend/scribble all over it.



I am thinking of making a hammer form to simplify the process as I'm not sure my skill/patience will match yours.

Regards
Drew

[JTR70]

Thanks a lot Drew! Yes, the pins do stand up a bit. I'll get a detailed shot of that for you. WOW! That's a nice CAD diagram! The one detail that really stands out as being incorrect is the pocket orientation. Most of the inner lip of the pocket except for a last little bit down by the tip is one with the 90 degree edge down in the seal channel. At least that is the way it was on '54 Speedster #54 which is the car I made these impressions from.

You can see here that its one in the same with this flange then just a few MM's before the tip it turns away.

If your up for some Low-tech help I'd be happy to send you these plastic models and the template I made.

As of this afternoon (7/2 I have just about got this last pocket all but dialed in. One more session should do it. Anyway I won't have any further use for them on this project and can always make them again If I ever need to. Just let me know. Justin

[Drew.s]

Hi justin
Thank you very much for the kind offer, I would very much appreciate the loan of your moulds and would pay for shipping to get them to me in the UK and send them back when I've completed the hammer form.
One request. Could you take a picture of the finished piece as straight on as you can get preferably with a milimeter ruler on the same plane?
This will help get it spot on.
Ping me a mail and I will send you my address.
My email is: drew.saunders@fcbinferno.com

Thanks again.
Drew

[JOP]

Hi Drew
Do you need more photos or measurements from a Real Speedster
Then I can help you if you want....its a total renovation going on this body.
Ex US history. Just let me know
/ Per

[bbspdstr]

This is of the crashed left side windshield post mounting of 84255, as fixed by me after I bought it and installed a Speedsterized C Coupe door with a bunch of shims for the hinges...it was, after all, 'just a race car' back then. I thought a picture may be of some interest before I re-glue the seal back on today.

-Bruce

[JTR70]

Sure thing Drew, I'll email directly.

Nice offer Per, Its a great luxury to be able to reference factory stuff.

Bruce, Thank you for posting this photo!!!!!
After looking at Drew's diagram and Trevor's new speedster posts/pockets I thought I may have gotten the inner detail of the cups wrong or was thinking that '54 Pre-A style may have been different. After looking at your photo its clear that from 80054 to 84255 is the same design. Most of the inner run of the cup is incorporated and washes in with the channel section. Thank you for confirming this and easing my mind!
Thanks again!! Justin

[JTR70]

Drew, here are a few more close ups of the door top ferrules and the straight-on shot of the A-pillar you asked for with scale. Sent you an email for your shipping address. Justin












7/29/14
Right pocket continued.

Only had an hour to play with it today so this time was spent tightening up the lines and bending the flanges.

The shape is close with just a few more contours to tighten up.

Should have the shape finalized by tomorrow. Thanks for looking! Justin

[Drew.s]

Hi Per, Bruce and Justin
Thanks for all the offers of pics and measurements.
The more data I can get from original cars the more accurate the drawing/form will be.
Shots square on and with ruler ref (like Justins) are really useful.
Outside diameter and length of pin locating tube would also be helpful.

I will update the drawing in a couple of days and re post.
Regards
Drew

[JTR70]

Thanks Drew! Getting the templates in the mail for you tomorrow.

7/31/14
Right pocket and A-pillar conversion continued.

Relief cuts at the top to get the last bit of contoured shape I need.

Excess metal trimmed and now ready to be welded back up.

Basic shape and contour completed.

Double check against the shape of the mold; close enough for Gov't work.

These two are now ready to be grafted together but have to get the frame prepped first.

Tedious job of removing the mount flanges of the original panel.

Initial holes cut for the pocket in both the closing panel and Frame. Continuing the fitment of all three pieces tomorrow. Thanks for looking! Justin

[JTR70]

8/1/14
Right A-pillar conversion parts now ready for final assembly.

Pocket fully clearance and seated into the pillar frame. Again I find it much easier to fit it in alone versus trying to fit it as unit with the rest of the closing panel. You can see at the bottom that I still have a bit of rust to fix before I can close it up.

I was having a few fitment issues with my initial closing panel. The main problem being that the lead on the outer edge was cut a bit too short and was not going to completely wrap around the frames leading edge. I thought about just forging ahead but I just wasn't happy with it. Something I read in Ron Fournier's metal shaping book years ago ran through my head. It was along the lines of what makes difference between a great and clean metal repair versus a ratty cobbled together repair relies heavily on the fabricators willingness to throw a bad part away and begin again. I took his advice and began again.

All three pieces sandwiched in together and fitting pretty well here.

I can begin grafting the new closing panel with the pocket tomorrow. Thanks for stopping by! Justin

[JTR70]

8/2/14
Right side closing panel and pocket welded.

Final trimming and fitting to both the pocket flange and new closing panel completed. Mounted up flush into the frame to ensure proper orientation. Clamped and ready for some tack welds here.

New parts all welded up

Final prep and repair of the cavity next then this piece goes on for good.
Thanks for looking! Justin

[JOP]

Orginal picture

Slightly distorted pictures with measurements

Any questions just let me know

[JTR70]

Per, thank you for taking the time to take a few measurements. I'm sure the next guy who is thinking about this conversion will appreciate that!

8/4/14
Right A-pillar closing panel mounted.

New panel and pocket acid dipped clean, prepped for plug-welds and ready to mount for the final time.

Clamped into position and began plug-welding the inner channel to the frame first.

with the inner section welded and set I began spooning the outer flap around the frame as originally done.

A quick test fit of this frames "new" speedster door just make sure there were no issues. So far so good.

New Speedster closing panel set.

Leaving the top portion loose for now. Final shape and height will be completely dependent on the new dash cowl position and its relationship to the fully mounted and adjusted door. A little further down the road...

Received a correct A-version rear floor pan from Rusty Tubs on Friday. An incorrect B/C rear pan came with the chassis the day it arrived.

With both A-pillars back to even with each other I'm going to switch gears for a bit and finish up the floor and tunnel repairs.

Spent the last part of this session positioning this pan section for fine trimming along its edges. Continuing its installation tomorrow. Thanks for looking! Justin