Projects winter project - "so let's chop a 40 coupe (and fab everything else possible...)

You're a moving target brother! Love how you sneek that sbf in the background of the pic. Go, man, go!

 

been awhile since I tuned in...

all I have to say is wild!

 

bitchin'!!!!!!!!

 

Okay here's a the lowdown on what's been going on with old rusty.

First off this will for sure get some shock and awe.
I'll admit this is definitely hack compared to high end work that is posted up here,
but this is something I've experimented with for many years now.
I've used this same method in a salty work boat marine environment,
and over time and abuse it has worked wonders.
The worst case is everything flakes off and I'm back to old rusty!

So the window rubber pushed me to figure out what to do with the surface.
The least I needed to do was coat the frame area.
At the old shop I had tried some sandblasting,
and the amount of media/sand needed was way too much,
and the rust seeded way too deep.
A quote of $1200+- is definitely not in my budget,
and even then I wouldn't trust them to not get lazy in certain spots,
or warp the heck out of the panels.
Dipping was probably the best answer but too late for that.
Instead hours were spent wire wheeling, sanding, scouring etc. the whole top.
After that a OSPHO rust converter was brushed on,
and then this very liquidy wipe on sealer.

Now it was time to cross the line.
My favorite epoxy sealer was rolled on.
The first batch is thinned out,
helping it to seep into the grain.

I did say rolled on!
These little rollers work wonders.
The trick is to roll right before dusk,
then there is less chance to get the rolling ridges.
Also this slows down the epoxy kick and it seems much stronger than a hot batch.

After that the majority of the primer was sanded off.
Basically it's a filler primer.
A different color coat rolled on after that.
This is an unthinned layer.
After some sanding,
I filled some minor pits and dinks with this crazy epoxy filler.
Totally different then polyester based it takes 3 hours to harden,
and a batch doesn't kick off on the plate.
The idea is to get the epoxy to completely suffocate the steel so the rust doesn't grow.

The rain gutter area had been basically tacked every inch.
Very difficult to do as the gap was quite large.
My first thought was to use a soft filler that would give a little,
but this stuff is super strong and if it cracks it cracks.
Again the majority of the second coat was sanded down,
and the third grey coat rolled on.

Supposedly this stuff takes 3 days to cure,
but is sandable the next day.
Each coat was slapped on as close as possible to keep the chemical bond.

Crazy chit this stuff is.
Earlier I had mixed the grey and red to make the brown primer that was rolled on the back half.

Now I'll let it cure up and not think about it.
We'll see how long this lasts!

TP

 

Now for some metal cutting.

These were the last gaps that needed to be filled,
especially before the window install.

A couple templates and some 1/16 sheet was cut out.

the disintegrated seal lip needed rebuilding as well.

both sides were welded up,
burning off all the new paint!

At least it was all steeled up.

Then some primer coated to match the outside.

TP

 

Too deep into my evening rum & OJ to completely follow all that Travis, but I have the utmost confidence that you know what you are doing.

I wonder, though . . . isn't rust encapsulator your friend? My understanding of the stuff is that it binds the iron up with phosphate (iron phosphate), thereby prohibiting the iron from bonding with oxygen (iron oxide). Of course (seriously), I am a rank amateur when it comes to this stuff. You say "marine" and I say holey chit! it's got to be good!

My mind is still blown that you're juggling two at once.

 

The hood had been progressing throughout this whole ordeal.
Last time posted it looked like this.
The project haunted my subconscious.

For the past weeks the hood nose was mocked up to help visualize.

Instead of going forward,
I had to go backward first.

As usual making more pieces to weld up.

Cutting out the flat spot in the center,
the two sides were welded to a peak.
Now the hood fit the grille and fenders a bit tighter.
At this point I really wanted to fit and weld the top half back on.
First a stiffener was needed,
much easier to make with top access.

Some 5/16 SS rod was used,
matching the bracing that holds up the front fenders.
This piece keeps the hood tighter to the fenders.
(even though the hood is bolted to the fenders right now!)

Here's the weird part.
When the original nose piece is mocked up,
the match line is over 2 inches higher than before.
Seems like the front to back slide,
also somehow section or pie cut the height.

TP

 

Now it was time to stick it together.
The handy clamps really help out.

Some early evening tacks and there was no turning back.

There is a little weld gap,
but I don't mind as it shrinks it straight instead of bulging.

Here's a kid pic of my high-tech facilities.
Yeah work right on the edge of the alley!

This fancy wind-block also shields any blinding light from passers by.
Also kinda adds a little upscale chic to the whole situation.

So every evening I'll try to get a little welding done.
Really I'll end up removing and weld it off the car.
If you know the green 40 post,
I'm starting to turn toward it a little.
If I can get it out of the garage,
then this can take it's place.

All caught up now!

TP

 

Wow it's only 3:30 here and your making me want one!
I'm digging cranberry/OJ and some Bacardi Añejo for later though...
I believe that the rust converter is definitelyl my friend.
Later in the game I'll prep the interior as well,
so the air/water doesn't sneak in from the back side,
which is usually how body cancer spreads.
I think this will give a really good seal at least for a couple years.
I'm not looking at getting a pro shiny paint though,
the goal is really to limit the work and have a somewhat smooth body.
I wouldn't call it juggling,
its more like throwing one as far forward,
then working on the other one before it falls into shelf duty!

TP

 

What an incredible build, like others I thought the chop was a practice run. Seeing what you've got now, I'm glad it wasn't, Keep up the great work.

 

again, right on, do it your way!

 

Practice run?? You never practice with art. This thing is a masterpiece.

 

Damn....I look away for a couple of days and POW!!! You go and do all of this!! This is really coming along, Man. The hood looks great!!!

 

Lurking and learnin..

 

Your choptop is really greatly done!! and I like those headers protruding through hoodsides! Keep going MAN !!!

 

one word VERY COOL !!

 

That's two words.

 

Ok guys here's the august update.
Again progress is slow an steady...



Last time I updated the hood was in pieces.
It still is.
I had a little sound concern as the neighbors just had a new kid.

Instead the filler that I had burnt off doing the windshield welding was replaced,
using the epoxy "quickfair" instead of the evercoat stuff.

Then I did one of the bigger mistakes I've done yet.
This green primer was scrounged off some old boat job.
Well not all solvent based epoxies are created equal.

If you've been reading,
my typical roll-on application is right before dark.
The worst time to paint,
however the grey or red amercoat will kick off regardless.
Taking all precautions,
I mixed up this batch mid-morning after the steel had heated up a bit,
let it set to get the chemicals activated,
and dammit if this stuff took almost a week to be barely dry to the touch.
There were a couple days I thought the fix was going to be scrubbing it off with acetone.

In a way it was a blessing,
as it forced me to focus on the other project.
After a couple weeks it did dry up enough to work on it.

We got the window templates cut to fit,
a little too tight though but it's particle board so easy to file down.

The lucky find was this universal window rubber.

Anyway I lost momentum on the project for the final fit...

TP

 

Looking really nice! Keep at it. I've been watching your build since you started the bell housing fab. I love the work you've been doing on it!

 

Thanks Deluxe here's more!



For some reason I decided to swap the cars around,
which meant putting the kids to work.
Cool to see the side by side differences in a chopped and stock body.


I'm really surprised how low the green 40 is in comparison.
I may need to scrape up a dropped axle for the rusty one.


Only small stuff done.
The headlight buckets were finally mounted,
and I really like the '39 trim rings vs the '40 rings.
If anyone has any '39 deluxe lenses give me a shout!


A surprise package came from the "chocolate & cheese" owner,
in the form of a '37 sealed beam kit.
Thanks Dan!
They were gutted out,
and now I need to figure out how to mount the bulb housing in the old buckets.

After almost 2+ weeks of cure time,
that green paint had finally dried up enough to sand.
A slew of rattlecan coats ensued.


After a couple test coats of metallic brown primer,
the final color was this metallic cherry red,
covered by a ton of clear coats.


Another week went by to let things harden,
and then some wet-sanding and hand massaging with rubbing compound.

The finish was just shiny enough to look good,
and rough enough to hide any flaws.

While I was rubbing it out...
an idea popped up that I couldn't hold back.
There was no turning back on this little project.


Over the weekend I sketched out a simple pattern,
and went to town annoying the neighbors like a woodpecker.

I've never done any hammer engraving,
but this was the perfect time to try it out.
Definitely a beginner hack job.

The idea was to not get too much detail as the insert is so huge,
I didn't want to leave it half done.
This took almost 4.5 hours over 2 evenings.

Some aluminum 1/4-20 fasteners were made into button heads,
and everything bolted together.

This will be over-gauged that's for sure.
I'm glad to have spent the time tapping that insert out.
Way better then watching a couple movies!

TP

 

I like it! Looks good and adds character to the car.

 

The engraving looks just raw enough to be beautiful. Great look. Can't wait to see it finished.

 

Great build thread

 

well done travis!

 

Awesome......

 

Coming along nicely. Looking forward to seeing more progress.

 

Hey thanks guys!
Definitely the raw look,
good enough for a backdrop.

One of my kids got into it,
and pounded this little fob out.

Never too early!
TP

 

WOW
Just read this whole thread, keep it up, looks like it's coming right along!

 

Your updates are fast becoming my favorite HAMB thing these days, brother! You are a beast! Love your assistants.

 

Totally awesome, nice work!!!