1949 Merc Build - Any Ideas

Managed to get going with the Floor Panel Supports or Inner Rockers. When I removed everything on the right side it looked pretty funky so I decided to go deeper. Long story short, I will have to fab up all the support structure from the lower section of the A pillar panel. I machined up some flanges and doweled them to locate the lower hinge plate. Hinge plate removed and everything peeled back. Doctor Detroit here on the HAMB has helped me out big time with pictures from his car showing all the areas I need to repair. I put the Inner Rockers up in place to check out the fit. Hey Ether, do you have any pictures of these outer areas from your build? Thanks, Rhys.

 

Rhys, Hope these pics help with your rocker issues. I am really impressed with the work you are doing and always interested in how you are going to tackle the next issue. You have chosen a unique approach to customizing YOUR build. It is going to be very interesting how this one is going to turn out and me, for one, look forward to the end result. Dont get discouraged with some of the posts you get. You havent disappointed me yet and you have my full attention on this one, and dont be fooled, if you didnt have there's they wouldnt be following the build. Keep up the good work and with the right approach and proportion, its going to turn out awesome!!!!! I do have a some interest in how you are going to approach a couple future issues I see, but I believe you've got it covered!!!!! Let me know if you need anything else. Ether

 

Heres a couple of green mountain rockers, just a little more info to help ya out.

 

I am not in any way trying to usurp Ether as he is a master of his craft, but I thought these may be of some help -if only a little. I also used Green Mountain sheet metal. I did find that the distance from the bottom of the A-pillar to the frame is critical for proper gapping of the front fenders and hood. Be sure and put a drain hole in the bottom of the A-pillar. While you're at it.... sign it.

 

That`s what I'm talking about!!!!!!!!!!!! With Doctor Detroit, Ether and 19Fordy's pictures I feel like I am on the assembly line. These last group of pictures are exactly what I need. Thank you very much gentlemen. I am always amazed at the talents of HAMB members, 19Fordy looks like you went the `Full Monty`like Ether on your build, simply amazing. A side note here, but I think my rockers may be the `Green Mountain` variety, I purchased them from Mike Dundon. Again thanks all, the information is much appreciated, regards, Rhys.

 

Rhys, there is an incredible amount of detailed pictures in this thread of a Merc rebuild from the rust upward.

http://www.jalopyjournal.com/forum/showthread.php?t=230126

 

Thanks Lifestylz, I have been through that thread before but at the start of my project. I had forgotten about it and it was good to go through it again.
Hey, can anyone tell me if the Mike Dundon (Green Mountain) Inner Rockers are longer in the rear than they need to be to allow for the installer to trim out as required? I can get everything fitted up front to where it looks like it shoud be but I have about a 4" or better over hang at the rear. Also, do the three support sections on the inner rockers (see Ether`s last group of pictures) match up in position to the floor pan supports for the body mounts? Thanks, Rhys.

 

1. My Green Mountain Inner Rockers were 81 in. long end-to -end and fit fine. They "butt-up" to the rear outside surface of the rear inner fender well and did not have to be trimmed. The front end fit fine also.
2. Yes, the support sections of the Green Mountain Inner rockers did 'match up" with the original floor pan supports. The second and 4th photo shows the original floor pan support and another floor pan support with frame bracket that I made since I noticed there were 4 extra holes in the stock frame to do so. The bracket closest to the top of the photo is the extra one I made. The other bracket is stock. My previous post shows the front end of the Green Mountain Inner Rocker panel (painted black) without the end cap. I did not have to cut anything off the GM inner rocker. I guess mercury used the same frame for all their cars.

 

Thanks for the pic's and measurements 19Fordy. I'm going out in the Garage with the printed copies now to measure everything out. Much appreciated, Rhys.

 

Managed to clear the old structure out and fab up the new on the `A`pillar panel extension. All tacked in using the hinge Jig to locate. Just need to patch and clean up this last panel and then back to the inner rockers, regards, Rhys.

 

Wow! You are really making progress. Is there a way you could hang the doors on the car to make sure the will line up" properly?

 

Yes, that`s a good idea 19Fordy. I will probably have them on and off a good few times as I install the GM inner rockers. I have a slight bit of play in the hinges and hinge pin. I was going to drill slightly over size and ream out to fit new pins. I could machine up some pins but is there any after market stuff for this kind of thing with the Mercs? Thanks, Rhys.

 

There is a guy on ebay who sells replacement pins. also saw once or twice guys who rebuild Merc hinges. Not cheap. I will look for the info. if you desire. I made new pins by turning down stainless bolts. I never could find any NOS replacement pins.

 

Managed to get the Pillar Extension Panel Cover and Inner Rocker tacked up on the right side. Fitted the Door up and found that I have the lower hinge slightly proud. I will have to recess it back 5/16" to get proper alignment. I now need to fix some previous repairs to the right quarter panel and finish weld everything out. Regards, Rhys.

 

The door is all aligned and gapped out really well (just needed two hundred pounds of persuasion in the right places). Brought out the front fender to fit it up but found it had a nice crease right at the door side edge, dang it, right in the spot I needed true. I banged it around for a bit and bolted it up. The gaps are off to the door edge. So a little more massaging on the A pillar extension panel flange and hopefully it comes in better. I think I will grab my salt ridden, rusty Ontario fender for the next fit up so that I am not fighting to many variables. All for now, Rhys.

 

Did not feel like playin in the rain pulling panels out of the shed today so I left the front end work for another day. I decided to remove a previous patch panel on the inner rocker at the rear quarter panel (it was a lap joint patch panel, I hate lap joints - butt weld or nothing). Ready to weld in after the paint dries.

 

I am really, really curious to see a photo of the entire car from the front and rear with that extra 8 inches added to the middle. You are undertaking a huge amount of work and I can't see how it will look good when you are done? This seems like a time when a photoshop job BEFORE cutting would have been a really good idea. (Speaking of which, can someone do a quick photoshop of a chopped merc widened 8" in the middle and post it so the rest of us can visualize this beast?)
The hood alone is going to be...well...interesting to say the least.

 

No photo shop required, the car is widened out and complete. The Merc is widened 5-1/2". The hood will not be widened the full five nor will the deck lid. Infact, I don`t think I will widen the deck lid at all. I may just extend out at the belt line to accomplish this. The hood may look something like below when all is said and done with the required sections and pie cuts.

 

Fit up my old front fender and I am happy with the gaps, I can now finish weld everything out up front. I continued with the rust repair at the back end. I just have the `B`Pillar extension to finish off and tie into the inner rocker on the right side and then I can start all over on the left side, Rhys.

 

Nice workmanship Rhys ! When do you expect to mate it to the Lincoln suspension?

 

Steve, it looks like late November. I head into an eight week outage at the Power Plant on September 18th. So the push will be on to finish the left side and then get the Gantry set up outside on the driveway. If I can get it finished up earlier that would be great. Hopefully the snow does'nt fly early this year. I'd like to get everything back in the garage and set up for winter as early as possible. Man, I wish I could match Ether's pace, both inner and outer rockers and a full chop on his brother's Merc in nine days. How is the 47 coming along, I'm watching for updates? Well, back out to the garage, Rhys.

 

Finished off the 'B' Pillar extensions and got ready for the other side today.

 

Rolled the Merc out on the drive and flipped it around to attack the left side. It looks just as bad. Oh well, time to smack it into shape. Regards, Rhys.

 

Cleared the left side of inner rocker, outer rocker and rotten structure, Rhys.

 

Looking great Rys! Not any real progress on the 47, redid the 51 Chevy I got this summer, and trying to get a bunch of stuff done around the house as well as some more insulation ,poly and heat for the shop I stripped the lemans parts car and have picked up a few things for it, if ya wanna call that progress lol! But I will be back on it before the snow flies. I finally scrounged up a free furnace for the shop so If I can stay a little warmer this winter I will get more done!

 

Still plugging away on the left side inner rocker area, lot's to go, Rhys.

 

Rhys is that zinc chromate primer? If so can you still buy it or has it been outlawed like all the other good stuff?

 

I'm sorry, but this build sucks. All this work just to end up with a lame street rod, with a quasi-modern drivetrain. Aside from a crusher there is no way to fix this build at this point.

You do some nice work, but man do you have some lousy taste.

 

Still working away. Everything tacked in to fit doors and fenders for gaps. Regards, Rhys.

 

You are certainly doing a nice fabrication. Thanks for keeping us posted.