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Projects ‘51 Mercury Botched Top Chop Repair

Discussion in 'The Hokey Ass Message Board' started by ClutchDumpinDan, May 7, 2022.

  1. X38
    Joined: Feb 27, 2005
    Posts: 17,498

    X38
    Member

  2. Looks like this project landed in good hands.
     
    OahuEli, 54delray, Stogy and 4 others like this.
  3. 51504bat
    Joined: May 22, 2010
    Posts: 5,569

    51504bat
    ALLIANCE MEMBER

    The way things are going I might have to rethink my old boss's go to line "you can't make honey out of dog shit" Very impressive work so far. Can't wait to see more progress.
     
  4. A Boner
    Joined: Dec 25, 2004
    Posts: 8,129

    A Boner
    Member

    …..even when the bottom 6” of the body is rusted away!

    Looking really good…this Merc is back on track!
     
  5. I’ve got one I hope to chop soon. But the rockers come first.
    I was taught to repair structural, align gaps and metal finish a body before any custom work could start.
     
    indyjps, 54delray, Stogy and 18 others like this.
  6. And that's what a lot of folks don't get!
     
  7. Nailhead Jason
    Joined: Sep 18, 2012
    Posts: 4,507

    Nailhead Jason
    Member

    Is this the one that was in the back of Dougs shop before he closed up?
     
    guthriesmith and ClutchDumpinDan like this.
  8. This is the only way to do the job right, anything else is just Hack Work by people that shouldn't begin to start with.
     
  9. Bad Bob
    Joined: Jan 25, 2006
    Posts: 24,333

    Bad Bob
    Member
    from O.C. Baby

    LIKE PUTTING A PUZZLE TOGETHER......WITHOUT THE LID!!! HAHAHAH
     
  10. Mr48chev
    Joined: Dec 28, 2007
    Posts: 35,840

    Mr48chev
    ALLIANCE MEMBER

    Dang, that Merc roof looks 100% better already.

    As far as gas welding the top, I welded mine with gas in 1980/81 and the structural welds never gave me an issue with not the easiest life for my truck over the years. The issue for me was not thinking some things out as well as I have should. I've learned ten fold on how to do things right since then.
     
    chryslerfan55, Stogy, vtx1800 and 3 others like this.
  11. spanners
    Joined: Feb 24, 2009
    Posts: 2,197

    spanners
    Member

    Nothing wrong with gas welding but I must admit I'd tack with mig and then gas weld to finish.
     
    vtx1800 and ClutchDumpinDan like this.
  12. ClutchDumpinDan
    Joined: Oct 8, 2006
    Posts: 2,116

    ClutchDumpinDan
    ALLIANCE MEMBER

    Alrighty. Now where’d we leave off?

    Not knowing what was where and how it got there. I got the car leveled up…

    9819255A-0DB3-46CB-ADF1-B14A90874801.jpeg


    So I could run a string line and make sure everything was centered up…

    02AB04EB-C3CB-4D9F-BD2F-9091F2111F87.jpeg

    Needed some work to get the post lined up once the roof was centered…

    F155DC6C-2849-4388-9B04-7810AA7CC5B2.jpeg


    Got it all lined up…

    5FAE5335-F082-49C4-94FD-2A4A3A517B02.jpeg

    Since I didn’t do the initial layout and cutting. I wanted to make sure that everything was the same side to side. So I made a paper template. And then transferred that to wood.

    B58DCA64-9088-4DB7-A957-6C1CEFBD6B7C.jpeg

    89E5322E-CD47-420D-BBA8-A7879B4F5EA0.jpeg


    With the wood template I can just flip it over to the other side of the opening and make sure they’re the same. And once they are the same side to side. They’re ready to tack in place…

    F0621E5B-B88D-4B9F-A080-55BFEF949674.jpeg
     
    Last edited: May 26, 2022
  13. Squablow
    Joined: Apr 26, 2005
    Posts: 18,397

    Squablow
    Member

    Solid update. The windshield glass template to check side to side is a great idea that I'm not sure I've seen before.
     
    54delray, Stogy, Torkwrench and 6 others like this.
  14. Did it once on a 32. Made the WS template out of MDF. It was sturdy enough to hold the roof pieces in place. Template was made from an unchopped windshield frame but shorter. It was used during a brookville body assembly and during construction chop. Centered the pattern with the body centerline (laser) this helped align both un-welded a-posts.
     
    OahuEli, chryslerfan55, Stogy and 4 others like this.
  15. Mr48chev
    Joined: Dec 28, 2007
    Posts: 35,840

    Mr48chev
    ALLIANCE MEMBER

    That windshield opening template shot is one I am saving for the info file. With the Here is how Clutch dumpin Dan did it.
     
  16.  
    ClutchDumpinDan likes this.
  17. Looks like yer just about ready to start welding the glass. :cool:
     
  18. ClutchDumpinDan
    Joined: Oct 8, 2006
    Posts: 2,116

    ClutchDumpinDan
    ALLIANCE MEMBER

    I have a couple chopped tops worth of experience at this point. But it’s all just metal. Measure twice, straight edges are your friend and only take pictures of the good parts ;)

    Good eye. This is the one.

    Worth doing in my opinion. I like to double check everything is the same side to side when chopping a “round” car. And once the chop metal work is done the template gets trimmed down to use as a glass template.

    Ah, that’s an interesting idea. I like that a lot.

    :D
     
  19. ClutchDumpinDan
    Joined: Oct 8, 2006
    Posts: 2,116

    ClutchDumpinDan
    ALLIANCE MEMBER

    So with the roof all centered up and tacked in place up front. I got the c-pillars trimmed and tacked in place. I made a wood template for the rear window openings like I did for the windshield. I’m glad I did as they were rather different. Some trimming off the c-pillar got them lined back up and even.

    60181737-B93C-4A08-87FA-20A028FA7456.jpeg

    With the roof in place and tacked in good. There was still some thinking about rear window openings and position going on. So I opted to keep things moving forward and went to work on the b-pillars…

    A9B7A9C4-3E09-4581-9658-ADF2C2B54436.jpeg

    Got the doors fitted up decent. Then got the pillars slanted forward and tacked in place…

    A9679CA7-833C-4B1E-BDEF-51EA3387E942.jpeg

    And the same on the drivers side. I’ll come back and do the corner radiuses later…

    F771CF98-6DE8-4C28-B980-71E08F4E73A4.jpeg

    752A4530-C843-4BB4-B3BE-F7D785441D87.jpeg
     
  20. X38
    Joined: Feb 27, 2005
    Posts: 17,498

    X38
    Member

    Save coming along really well. :)
     
    54delray, Stogy and ClutchDumpinDan like this.
  21. Awesome . Keep them updates coming
     
    54delray, Stogy and ClutchDumpinDan like this.
  22. Gizzy
    Joined: Jan 20, 2008
    Posts: 770

    Gizzy
    Member
    from N.W,Ohio

    Nice work
     
    Stogy and ClutchDumpinDan like this.
  23. Gasser 57
    Joined: Feb 13, 2007
    Posts: 1,287

    Gasser 57
    Member
    from New Jersey

    Man, beautiful work. What a save!
     
    Stogy and ClutchDumpinDan like this.
  24. 38Chevy454
    Joined: Oct 19, 2001
    Posts: 6,767

    38Chevy454
    ALLIANCE MEMBER

    Great save and nice to see all the pictures with explanation of the process. Showing what is required and how to do it correctly may help another person doing their chop. I like that window template idea and flipping it side to side to check for same opening. Going to have to remember that idea.
     
  25. BJR
    Joined: Mar 11, 2005
    Posts: 11,190

    BJR
    Member

    Wow you are doing an amazing job saving that car.
     
    Stogy and ClutchDumpinDan like this.
  26. 49ratfink
    Joined: Feb 8, 2004
    Posts: 24,299

    49ratfink
    Member
    from California

    first time you have the car out somewhere the previous owner will be telling his pals he chopped it.
     
    Chrisbcritter, Stogy, X-cpe and 7 others like this.
  27. 57JoeFoMoPar
    Joined: Sep 14, 2004
    Posts: 6,485

    57JoeFoMoPar
    Member

    Really impressive work so far. I'd have been thinking about trying to source a new roof and start from there, but your ability to save that hacked up roof is all the more impressive. Aside from the horrific chop that you're saving, the car actually looks really nice. Keep up the good work
     
  28. Primered Forever
    Joined: Jul 7, 2008
    Posts: 1,000

    Primered Forever
    Member
    from Joplin,MO

    That Merc is lucky that you found it!! Nice save.
     
    54delray, Stogy and ClutchDumpinDan like this.

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