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  #21  
Old 01-04-2018, 02:21 PM
Turbo57 Turbo57 is offline
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Ty for share this great build, i am learning every day i read all amazing thread in this forum
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  #22  
Old 01-04-2018, 05:27 PM
Charlie Myres Charlie Myres is offline
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Awesome work and I like the fact that you are largely self-taught!

Cheers Charlie
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  #23  
Old 01-04-2018, 06:45 PM
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Glad the build / pictures are enjoyed! I'm from a very small rural town, so there really isn't anybody else around that does the type of work I do / want to do. So it's a lot of trial and error learning as I go.

Fabbed up a small piece on the bead roller to match the profile lip of the windshield opening.

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Started trimming away the a-pillar and have the new windshield opening welded into position.

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Exterior a-pillar skin fit and tacked into position. (The inside of the header was cleaned and epoxied before installing the front roof skin)

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Front roof skin and side panel above door also fit and tacked into position.

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Rear roof corner scribed and removed.

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Rear corner final fit and tacked into position.

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All pieces of the roof (driver's side) are tacked into position. Now to fit and trim for the upper cab jamb.

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Trimmed all roof skin panels in order to fit the upper cab jamb that I had started to fabricate earlier in the project.

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All roof panels and upper cab jamb installed and checking upper door gap!

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Nice even gap all around the door top! Effort well worth it!

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Nice flow from all roof panels down around and into the top of the door.

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Welds planished and finished. Now to do the other side and the rear panels above the rear window!

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Last edited by pplace; 01-04-2018 at 08:37 PM.
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  #24  
Old 01-04-2018, 08:52 PM
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pplace pplace is offline
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Default Finishing lower door skin

Looking back I'm amazed I don't have any pictures of fabricating and shaping the exterior door skins from the windows down?!?! This was obviously a fairly involved process, and as well documented as I did the rest of the build (I obviously have many more pictures of the build than I'm able to share here. These posts are directed more towards the metal work portion of the project)

Sorry for the lack of process pics here....

I did fabricate 100% of the exterior skin below the window (previously you saw how I did the door top / window opening portion)

I created the door skin in two parts:

1. From the window down to the fender body line / fade away.
2. From the fender fade away to the bottom of the door obviously.z
These panels do look fairly "flat" except for the curve to the window and the fade away, but there certainly was crown added both vertically and horizontally to keep the correct flow of the cab in each direction and to also ensure some "strength" in the door skin itself.

The panels were shaped, then welded together and the fade away "dialed" in on the English wheel, etc. Once the skin was final shaped it was hemmed over the door shell just like I did on the top (and spot welded in multiple spots to "lock" it in.

I was very happy to end with very nice even door gaps both in "width" but also flushness to the surrounding panels....whew!

I remember feeling so proud and happy at this portion of the project. It was really coming along and starting to look like something to be proud of!

I realized I never added a picture of the project how it arrived to me. I'll add one to show how I slightly changed the "chop" or look of the roof. Previously the door window opening was very rectangle (top and bottom edges were basically parallel) In order to give a nicer look I subtly lowered the front a bit in the process of building the door jambs, doors and remaking the roof skins. The finished result gives the window opening a slight "wedge" front to back. Much better appearance to my eyes.

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Rush too much trying to get to the end when the end is closer when you take your time.

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Last edited by pplace; 01-04-2018 at 09:10 PM.
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  #25  
Old 01-05-2018, 03:30 AM
Gojeep Gojeep is offline
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When part of a build, there is a lot of interest in the rest of the fabrication too, not just panel shaping on this site. We all have to do that part of the build as well and there is a lot to learn from each other and the different way we do things. So if you can spare the time, would be great to see that added to the thread.
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  #26  
Old 01-05-2018, 07:30 AM
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pplace pplace is offline
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Quote:
Originally Posted by Gojeep View Post
When part of a build, there is a lot of interest in the rest of the fabrication too, not just panel shaping on this site. We all have to do that part of the build as well and there is a lot to learn from each other and the different way we do things. So if you can spare the time, would be great to see that added to the thread.
Ok, I was curious about that. Since this is a metal shaping forum, I wasn't sure if that was the only thing the posts should focus on for the most part.

I've only got a couple more posts / updates in regards to the sheet metal portion of this project that I did. After that, I'll look through the photos and fill in some of the smaller details, then go back and show / explain what I did on the chassis, etc.
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  #27  
Old 01-05-2018, 07:46 AM
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Steve Hamilton Steve Hamilton is offline
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Dane
Sheet metal shaping is the focus here on allmetalshaping, but we encourage members to post complete projects such as yours.

A project needs a good foundation to mount all the sheet metal to. Chassis, floors, body structure, core support,etc. are just thicker gauge sheet.

Our policy is that all phases of a complete build project are acceptable to post.

Please share what you have, our members enjoy seeing this type of content.

Steve
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  #28  
Old 01-05-2018, 09:49 AM
Mike Motage Mike Motage is offline
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Cool project, thanks for showing!
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  #29  
Old 01-05-2018, 01:29 PM
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Default Custom grille

Now that the majority of the body was "dialed in" I moved on to creating and updating the styling of the grille opening. I wanted to retain some of the original character, but knew the original setup was too "bulky" looking for this project. I also wanted to incorporate the "iconic" Dodge vertical & horizontal grille bars.

An example of a grille / parking lamp

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A modern example of the to me "iconic" Dodge grille.

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My clean slate to start with (I had already fabricated and shaped all the interior grille metal work to form around the radiator / A/C condensor.

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A foam mock up that I carved to visualize the look I wanted. The center vertical does still play a bit off of the original cast center pieces.

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From left to right:

~An original horizontal grille bar
~The foam mock up bar
~My sheetmetal blank cut and ready to shape.
~A new grille bar

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Horizontal grille bars attached. I've created a hidden framework to mount the grille with all hidden fasteners, as I wanted to have a "floating grille" look when finished.

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Here you can see one of the brackets that goes back and bolts to the radiator support. Notice also how the grille bar ends "float" away from the grille surrond. This end was later capped off with sheetmetal, but still retained the gap.

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Holding the original cast center section and upper grille bar in place for comparison.

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Wanted to incorporate a modern emblem into the center grille piece, so I created this quick and simple stamping die to press a bead into a flat sheet.

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A stamped piece with the emblem inside. Good enough fit for now.

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From left to right:

~Foam mock up
~Paper template taken from mock up
~Sheet metal blank cut out and ready to form.

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Started forming some of the bends. I also have now grafted in the pressing for the emblem. The center behind the emblem was later "flattened" a bit to as well as the emblem back angle sanded to allow the emblem to fit on the slight peak.

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Center grille piece all finish formed, welded and also vertical beads added to tie into the look of the original cast piece.

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Complete grille installed. If you look at the upper left grille opening you will see I test formed a black perforated sheet that will be the grille screen design.

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Close up view shows the perforated sheet a bit better.

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Close up of just the perforated sheet with the rolled edges for a softer / fabricated look when installed.

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  #30  
Old 01-05-2018, 05:08 PM
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Default Radiator / grille opening

Sorry, but I'm going to jump back in time out of sequence from the previous posts. This post will focus on the radiator support and fabricating the front grille opening to blend into the radiator support.

I also added what I did for the headlights as I only have two pictures of what I did as it wasn't anything too complex.

Here is a picture showing the radiator support I built. It mounts both the radiator and A/C condenser.

I also modified and fabricated the front frame horns in order to lower them enough to drop the radiator more vertically centered in the grill opening.

I built and incorporated some horizontal support bars that go from the top of the radiator support back to the cowl side. This was necessary as I had the entire one piece front sheet metal mount to the radiator core support, so I wanted to make sure everything was nice and strong.

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The side view shows the drop that I built into the front frame horns. Also shows the top mounting brackets fro the horizontal support bars and how they attach to the core support.

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Here I've already fabricated up all the small intricate parts and pieces that wrap around the grille opening and end up transitioning to mount around the radiator to the core support.

The A/C lines and fittings top and bottom shoot straight out and exit through the flat vertical pieces at the top and bottom of the opening (holes not drilled yet

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Another view showing how the bottom portion of the grill opening flows from the opening to the radiator.

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This one shows how it transitions to the top of the radiator.


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With the front sheet metal off and looking from the back side you can get a better understanding of what's all going on. What you cant see are three mounting holes on the straight vertical edge pieces. These match up to three mounting holes on the vertical posts of the core support.

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The headlights were french mounted. I slightly modified the opening and bucket in order to mount everything from inside the fender.

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The original headlight trim rings were pot metal, so I found some basic steel rings (I don't recall where I picked them up) A little shrinking / stretching in some areas was necessary in order to get the correct fit and flow to the fender. After that it was as simple as tacking them on and welding the seam all the way around.

I didn't want a "deep" frenched headlight....more so just a clean mount with no visible ring. If I wanted a deeper "sink" I could just add spacers behind the fender flange if needed.

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Last edited by pplace; 01-05-2018 at 06:01 PM.
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