Sheet Metal Fabrication
These are examples of hand formed sheet metal panels that I fabricated from flat sheets of 18 gauge cold rolled steel.
Sheet Metal Fabrication:
'72 Dodge Dart - The Dart is finished up and off to paint! I fabricated some patches inside the rear window lip and package tray, and also fabricated some patches in the trunk rain gutter.
'72 Dodge Dart - The Dart is finished up and off to paint! I fabricated some patches inside the rear window lip and package tray, and also fabricated some patches in the trunk rain gutter.
Sheet Metal Fabrication:
'72 Dodge Dart - This car is actually a Plymouth Scamp, but it's being built as a Dart. The last 20" of the left side frame rail had rusted away. My client hired me to fabricate the frame rail, tail pan, and trunk floor patches. The spring shackle mount was bought aftermarket, but I fabricated everything else.
'72 Dodge Dart - This car is actually a Plymouth Scamp, but it's being built as a Dart. The last 20" of the left side frame rail had rusted away. My client hired me to fabricate the frame rail, tail pan, and trunk floor patches. The spring shackle mount was bought aftermarket, but I fabricated everything else.
Sheet Metal Fabrication:
'98 Lincoln Town Truck - It's not everyday that a client requests a full custom! Uncle Nick decided that the rear seats in his town car were eating up too much trunk space. Lincoln Town Truck is the solution! The rear doors were welded shut, the roof was cut and moved forward about 25", and the bed was fabricated from the inside of an F150 truck bed. There are still some window trim pieces that need to be made, but so far this has been a very fun project that I think is turning out great!
'98 Lincoln Town Truck - It's not everyday that a client requests a full custom! Uncle Nick decided that the rear seats in his town car were eating up too much trunk space. Lincoln Town Truck is the solution! The rear doors were welded shut, the roof was cut and moved forward about 25", and the bed was fabricated from the inside of an F150 truck bed. There are still some window trim pieces that need to be made, but so far this has been a very fun project that I think is turning out great!
Sheet Metal Fabrication:
'41 Dodge WC - This truck doesn't get much sheet metal work done to it, since the original builders did such a good job making it a unique custom truck some 60+ years ago. Sometimes it needs new metal though! This is one of the reflectors on the rear of the truck, made with glass marbles as the reflecting surface. I decided to practice my skills and fabricate a new one from scratch. It weighs about 5 lbs. heavier than a modern plastic reflector.
'41 Dodge WC - This truck doesn't get much sheet metal work done to it, since the original builders did such a good job making it a unique custom truck some 60+ years ago. Sometimes it needs new metal though! This is one of the reflectors on the rear of the truck, made with glass marbles as the reflecting surface. I decided to practice my skills and fabricate a new one from scratch. It weighs about 5 lbs. heavier than a modern plastic reflector.
Sheet Metal Fabrication:
'98 Lincoln Town Truck - These custom fender skirts were made before the Town Truck became a truck.
'98 Lincoln Town Truck - These custom fender skirts were made before the Town Truck became a truck.
Sheet Metal Fabrication:
'41 Ford Truck - Rear cab corners all done. Hand fabricated sheet metal panels.
'41 Ford Truck - Rear cab corners all done. Hand fabricated sheet metal panels.
Sheet Metal Fabrication:
'41 Ford Truck - Door gaps need to look good before I chop the cab, and I can't set door gaps with rusty doors! The bottom hinges had rusted away from both doors and pillars, requiring extensive repairs. Up next are the rear cab corners, and lower cowl area, where the front fenders attach.
'41 Ford Truck - Door gaps need to look good before I chop the cab, and I can't set door gaps with rusty doors! The bottom hinges had rusted away from both doors and pillars, requiring extensive repairs. Up next are the rear cab corners, and lower cowl area, where the front fenders attach.
Sheet Metal Fabrication:
'65 Ford Ranchero - Hand formed quarter panel patches for the Ranchero. My client was happy with the cab floor I completed, so the quarter panel was next. Another successful job!
'65 Ford Ranchero - Hand formed quarter panel patches for the Ranchero. My client was happy with the cab floor I completed, so the quarter panel was next. Another successful job!
Sheet Metal Fabrication:
'38 Dodge Coupe - Sanded the rest of the front fenders and headlight buckets. Now its really starting to look like a complete car.
'38 Dodge Coupe - Sanded the rest of the front fenders and headlight buckets. Now its really starting to look like a complete car.
Sheet Metal Fabrication:
'38 Dodge Coupe - The coupe needs a bit lower roof line, but for now a visor will be a good compromise. I borrowed a '51 Pontiac visor from Chris that had the look I was going for, and used it as inspiration to make a custom one that fits just right.
'38 Dodge Coupe - The coupe needs a bit lower roof line, but for now a visor will be a good compromise. I borrowed a '51 Pontiac visor from Chris that had the look I was going for, and used it as inspiration to make a custom one that fits just right.
Sheet Metal Fabrication:
'65 Ford Ranchero - It was time for this awesome Ranchero to get some new floors. My client hired me to fabricate the floor pan patch panels since my prices were comparable to handmade panels offered through the larger suppliers. No shipping costs or delays either. Even though my work will be covered by a carpet, it will add some more strength and miles to a cool little truck!
'65 Ford Ranchero - It was time for this awesome Ranchero to get some new floors. My client hired me to fabricate the floor pan patch panels since my prices were comparable to handmade panels offered through the larger suppliers. No shipping costs or delays either. Even though my work will be covered by a carpet, it will add some more strength and miles to a cool little truck!
Sheet Metal Fabrication:
'69 Ford Mustang - Wrapped up the floor project in the Mustang. Next I will install some new brakes and the new interior panels I received with the car, and this thing will be ready to roll.
'69 Ford Mustang - Wrapped up the floor project in the Mustang. Next I will install some new brakes and the new interior panels I received with the car, and this thing will be ready to roll.
Sheet Metal Fabrication:
'69 Ford Mustang - This Mustang had what I thought was a small hole in the floor, but as I pulled up the carpet, it kept growing larger. Unfortunately, it went through the toe kick into the top of the torque boxes. I could have bought replacement panels for these locations, but wanted to practice my sheet metal shaping skills and didn't want to wait for shipping. The lines in the floor aren't perfect, but I put them in by myself with a hand crank operated bead roller and using a block of steel as a punch. I fabricated the top of the torque box with two layers of 18 ga. plug welded together.
'69 Ford Mustang - This Mustang had what I thought was a small hole in the floor, but as I pulled up the carpet, it kept growing larger. Unfortunately, it went through the toe kick into the top of the torque boxes. I could have bought replacement panels for these locations, but wanted to practice my sheet metal shaping skills and didn't want to wait for shipping. The lines in the floor aren't perfect, but I put them in by myself with a hand crank operated bead roller and using a block of steel as a punch. I fabricated the top of the torque box with two layers of 18 ga. plug welded together.
Sheet Metal Fabrication:
'38 Dodge Coupe - Smooth running boards will be a nice change. Originally they were covered with a rubber pad that had decayed a long time ago, leaving all the mounting holes exposed. Not a very clean look. Since I had the running boards removed to access the panels under the doors, might as well get started!
'38 Dodge Coupe - Smooth running boards will be a nice change. Originally they were covered with a rubber pad that had decayed a long time ago, leaving all the mounting holes exposed. Not a very clean look. Since I had the running boards removed to access the panels under the doors, might as well get started!
Sheet Metal Fabrication:
'38 Dodge Coupe - There used to be gaps under the doors that were distracting, so I fabricated some panels to fill the gaps and give the body a sleeker profile. Same as the fender skirts, I decided to use my TIG welder on the exposed seams and I really like the results.
'38 Dodge Coupe - There used to be gaps under the doors that were distracting, so I fabricated some panels to fill the gaps and give the body a sleeker profile. Same as the fender skirts, I decided to use my TIG welder on the exposed seams and I really like the results.
Sheet Metal Fabrication:
'38 Dodge Coupe - Fender skirts are completed and bolted in! I added a lip to the bottom of the skirt to help it hold its shape. I think the time I invested in this project was well worth it.
'38 Dodge Coupe - Fender skirts are completed and bolted in! I added a lip to the bottom of the skirt to help it hold its shape. I think the time I invested in this project was well worth it.
Sheet Metal Fabrication:
'38 Dodge Coupe - Fender skirts are almost finished. I wanted them to look like bubble skirts, but flush mounted with the fender. Similar design as a Lincoln Zephyr. I put metal pins in the top lip of the skirt that key into the lip on the fender. Two or three bolts at the bottom of each skirt will hold it up, and the metal pins keep it in place. I decided to TIG weld all the seams which is a more difficult and time consuming process, but I can achieve better results than with MIG (aka wire feed). Using a flat file instead of my air sander on all the exposed welds is going to give me a proper metal finished look!
'38 Dodge Coupe - Fender skirts are almost finished. I wanted them to look like bubble skirts, but flush mounted with the fender. Similar design as a Lincoln Zephyr. I put metal pins in the top lip of the skirt that key into the lip on the fender. Two or three bolts at the bottom of each skirt will hold it up, and the metal pins keep it in place. I decided to TIG weld all the seams which is a more difficult and time consuming process, but I can achieve better results than with MIG (aka wire feed). Using a flat file instead of my air sander on all the exposed welds is going to give me a proper metal finished look!
Sheet Metal Fabrication:
'69 Chevy Camaro - I had to fabricate lots of panels throughout this project, but these I'm the most proud of. I was able to eliminate a factory seam and a nasty seam from the last time the quarter panels were replaced. Very limited space to get behind these panels and knock out any mistakes, so it had to be right the first time. I think I nailed it!
'69 Chevy Camaro - I had to fabricate lots of panels throughout this project, but these I'm the most proud of. I was able to eliminate a factory seam and a nasty seam from the last time the quarter panels were replaced. Very limited space to get behind these panels and knock out any mistakes, so it had to be right the first time. I think I nailed it!
Sheet Metal Fabrication:
'38 Dodge Coupe - Finally took the time to nose the coupe. Eliminated every trim hole on the hood tops and most on the sides, removed the emblem hole where the hood meets the grille shell, and started to bring the front of the car down to bare metal. The different colored body panels are distracting. Eventually the whole car will be bare metal.
'38 Dodge Coupe - Finally took the time to nose the coupe. Eliminated every trim hole on the hood tops and most on the sides, removed the emblem hole where the hood meets the grille shell, and started to bring the front of the car down to bare metal. The different colored body panels are distracting. Eventually the whole car will be bare metal.
Sheet Metal Fabrication:
'38 Dodge Coupe - Here is the top secret project! I made a flying eyeball for the front of the 38. What better way to fill the old crank lever hole and and nice up two chrome wings than a real glass eye? And does it need to light up too? Yes it does. I designed this light to easily install into a 2" diameter hole cut into any sheet metal surface. It would be possible to use a marble, or laser etched glass plate, or something else transparent in place of a glass eye. Contact me today to make a custom creation like this for you!
'38 Dodge Coupe - Here is the top secret project! I made a flying eyeball for the front of the 38. What better way to fill the old crank lever hole and and nice up two chrome wings than a real glass eye? And does it need to light up too? Yes it does. I designed this light to easily install into a 2" diameter hole cut into any sheet metal surface. It would be possible to use a marble, or laser etched glass plate, or something else transparent in place of a glass eye. Contact me today to make a custom creation like this for you!
Sheet Metal Fabrication:
'38 Dodge Coupe - I finally made the panels to fill in the gaps where the headlights would have attached to the radiator shell on the '37 hood. When the entire car is bare metal I will call it the Silver Bullet! Up next is raising the top edge of the grille shell to match the height of the bullet panels, filling in the trim holes on the hood, and nosing the car to get rid of the hood ornament holes. Plus a top secret project that you will just have to wait to see...
'38 Dodge Coupe - I finally made the panels to fill in the gaps where the headlights would have attached to the radiator shell on the '37 hood. When the entire car is bare metal I will call it the Silver Bullet! Up next is raising the top edge of the grille shell to match the height of the bullet panels, filling in the trim holes on the hood, and nosing the car to get rid of the hood ornament holes. Plus a top secret project that you will just have to wait to see...
Sheet Metal Fabrication:
'38 Dodge Coupe - The hood sides didn't match up close enough with the fenders. The hood I'm using is from a '37 car, and some custom made extensions were the only way to close the gaps! I also added in bear claw latches on both sides to eliminate the latch lever and smooth up the sides. Now the sides open with cables under the dash.
'38 Dodge Coupe - The hood sides didn't match up close enough with the fenders. The hood I'm using is from a '37 car, and some custom made extensions were the only way to close the gaps! I also added in bear claw latches on both sides to eliminate the latch lever and smooth up the sides. Now the sides open with cables under the dash.
Sheet Metal Fabrication:
'38 Dodge Coupe - These fender skirts have taken a long time because I am having trouble getting the crown of the driver's side to match the first one I made. I want to make the skirts mount flush to the fenders, and I won't be cutting either fender until I am happy with the shape of both sides! We went through another 4th of July Parade with the new skirts clecoed in place. We got 2nd best vintage car this year, probably because the cooling fan shorted out and killed the engine in front of the judge's table. Then it became a foot operated float. Oh well, at least we looked good doing it!
'38 Dodge Coupe - These fender skirts have taken a long time because I am having trouble getting the crown of the driver's side to match the first one I made. I want to make the skirts mount flush to the fenders, and I won't be cutting either fender until I am happy with the shape of both sides! We went through another 4th of July Parade with the new skirts clecoed in place. We got 2nd best vintage car this year, probably because the cooling fan shorted out and killed the engine in front of the judge's table. Then it became a foot operated float. Oh well, at least we looked good doing it!
Sheet Metal Fabrication:
'78 Fire Truck - It took installing the dually bed I picked up in Reno to discover that cab and chassis trucks, with dual rear wheel axles, are actually more narrow than a traditional dually axle. All that extra fender for nothing! Traded Scott for the pickup bed from the same donor truck that I took the rear frame section from. Instead of fiberglass fenders I whipped up some custom sheet metal fender flares. Fiberglass is for weaklings anyways.
'78 Fire Truck - It took installing the dually bed I picked up in Reno to discover that cab and chassis trucks, with dual rear wheel axles, are actually more narrow than a traditional dually axle. All that extra fender for nothing! Traded Scott for the pickup bed from the same donor truck that I took the rear frame section from. Instead of fiberglass fenders I whipped up some custom sheet metal fender flares. Fiberglass is for weaklings anyways.
Sheet Metal Fabrication:
'38 Dodge Coupe - I had been fretting about if I was going to fill the trim holes, and how I was going to do it, since I bought this car. Go figure that it only took me one night to fill almost every one!
'38 Dodge Coupe - I had been fretting about if I was going to fill the trim holes, and how I was going to do it, since I bought this car. Go figure that it only took me one night to fill almost every one!
Sheet Metal Fabrication:
'38 Dodge Coupe - A '37 hood won't fit perfectly on a '38 without changing a few things. I started with a new radius on the corners where it meets up with the grille.
'38 Dodge Coupe - A '37 hood won't fit perfectly on a '38 without changing a few things. I started with a new radius on the corners where it meets up with the grille.
Sheet Metal Fabrication:
'38 Dodge Coupe - Getting the 38 ready for the road took a lot of little projects. Widening the running boards to match the front fenders, brand new exhaust system, and sealed beam headlights fabricated to fit into the old buckets. Will it make it 5 hours south? Even with some of the trip raining or after dark? There's a much better chance now!
'38 Dodge Coupe - Getting the 38 ready for the road took a lot of little projects. Widening the running boards to match the front fenders, brand new exhaust system, and sealed beam headlights fabricated to fit into the old buckets. Will it make it 5 hours south? Even with some of the trip raining or after dark? There's a much better chance now!
Sheet Metal Fabrication:
'38 Dodge Coupe - The driveshaft was scraping on the rear floor pan after getting lowered 2.5 inches. Not anymore!
'38 Dodge Coupe - The driveshaft was scraping on the rear floor pan after getting lowered 2.5 inches. Not anymore!
Sheet Metal Fabrication:
'38 Dodge Coupe - Frenching in the new rocket nosed taillight lenses. They seem a little small so I might add more...
'38 Dodge Coupe - Frenching in the new rocket nosed taillight lenses. They seem a little small so I might add more...
Sheet Metal Fabrication:
'38 Dodge Coupe - You might be able to go through one or two scorching hot parades without a floor, but sooner or later you need one!
'38 Dodge Coupe - You might be able to go through one or two scorching hot parades without a floor, but sooner or later you need one!
Sheet Metal Fabrication:
'38 Dodge Coupe - Shaved door handles and new bear claw latches! Starting to look like a real Kustom now!
'38 Dodge Coupe - Shaved door handles and new bear claw latches! Starting to look like a real Kustom now!
Sheet Metal Fabrication:
'36 Plymouth Coupe - Someone backed into this beautifully restored Plymouth! As luck would have it, I introduced myself to the owner of the car and he asked me to try and fix it! I think it turned out well and I'm proud to say this one is back on the road.
'36 Plymouth Coupe - Someone backed into this beautifully restored Plymouth! As luck would have it, I introduced myself to the owner of the car and he asked me to try and fix it! I think it turned out well and I'm proud to say this one is back on the road.
Sheet Metal Fabrication:
'38 Dodge Coupe - If you are like me you might think, "Trunk lid? How hard can that be to make?" Let me tell you it can be pretty darn hard! More hours than I would like to admit went into this panel, but I am pleased with the results. By far the largest and most difficult panel I've done yet. I still need to finish weld the seam and trim the edges but I like where this is going!
'38 Dodge Coupe - If you are like me you might think, "Trunk lid? How hard can that be to make?" Let me tell you it can be pretty darn hard! More hours than I would like to admit went into this panel, but I am pleased with the results. By far the largest and most difficult panel I've done yet. I still need to finish weld the seam and trim the edges but I like where this is going!
Sheet Metal Fabrication:
'38 Dodge Coupe - Found these awesome glass tail light lenses. Getting them ready to be frenched into the rear fenders
'38 Dodge Coupe - Found these awesome glass tail light lenses. Getting them ready to be frenched into the rear fenders
Sheet Metal Fabrication:
'38 Dodge Coupe - Driver's side door skin, B pillar, and quarter panel get the same treatment. Luckily there was less rust and dent repair on this side. Starting to become a solid car now!
'38 Dodge Coupe - Driver's side door skin, B pillar, and quarter panel get the same treatment. Luckily there was less rust and dent repair on this side. Starting to become a solid car now!
Sheet Metal Fabrication:
'38 Dodge Coupe - Passenger side quarter panel had rusted out at the bottom. New patch made, old panel smoothed out, and new patch welded in.
'38 Dodge Coupe - Passenger side quarter panel had rusted out at the bottom. New patch made, old panel smoothed out, and new patch welded in.
Sheet Metal Fabrication:
'38 Dodge Coupe - Passenger side door needed a bunch of dents smoothed out. Found a few holes in the bottom of the skin and also the framework of the door. No way around that but to patch it!
'38 Dodge Coupe - Passenger side door needed a bunch of dents smoothed out. Found a few holes in the bottom of the skin and also the framework of the door. No way around that but to patch it!
Sheet Metal Fabrication:
'38 Dodge Coupe - B pillar on passenger side was in a sorry state. Bent a piece of 3/4" tubing and welded it inside the pillar for heaps of strength!
'38 Dodge Coupe - B pillar on passenger side was in a sorry state. Bent a piece of 3/4" tubing and welded it inside the pillar for heaps of strength!
Sheet Metal Fabrication:
'38 Dodge Coupe - Patches for the front of the front fenders. Filled all the gaps with new metal and brought the fender body line down to match the grill. The grill shell is attached with bolts now instead of cleckos! Next is running boards, then hood gaps.
'38 Dodge Coupe - Patches for the front of the front fenders. Filled all the gaps with new metal and brought the fender body line down to match the grill. The grill shell is attached with bolts now instead of cleckos! Next is running boards, then hood gaps.
Sheet Metal Fabrication:
'50 Chevy Suburban - Front fenders for the Suburban are getting a much needed refresher. Started by pounding out all the dents, making patches, and soon they will be good as new!
'50 Chevy Suburban - Front fenders for the Suburban are getting a much needed refresher. Started by pounding out all the dents, making patches, and soon they will be good as new!
Sheet Metal Fabrication:
'38 Dodge Coupe - Running Board patches! This one was the worst of the pair. Eventually I will have to widen them to match the front fenders and replace all the metal on top for a smooth look. Ironically I formed the edges of the running boards on a frame section of a '40s Dodge truck.
'38 Dodge Coupe - Running Board patches! This one was the worst of the pair. Eventually I will have to widen them to match the front fenders and replace all the metal on top for a smooth look. Ironically I formed the edges of the running boards on a frame section of a '40s Dodge truck.
Sheet Metal Fabrication:
'38 Dodge Coupe - Small cars need small bench seats. Ford truck bench seat narrowed 17"
'38 Dodge Coupe - Small cars need small bench seats. Ford truck bench seat narrowed 17"
Sheet Metal Fabrication:
'38 Dodge Coupe - Widening the fenders to accommodate the wider tire track and turning the front clip sheet metal into one big piece. Now it's really getting serious.
'38 Dodge Coupe - Widening the fenders to accommodate the wider tire track and turning the front clip sheet metal into one big piece. Now it's really getting serious.
Sheet Metal Fabrication:
'38 Dodge Coupe - Lower cowl patch from scratch on the drivers side. Now there's plenty of strength to attach those front fenders!
'38 Dodge Coupe - Lower cowl patch from scratch on the drivers side. Now there's plenty of strength to attach those front fenders!
Sheet Metal Fabrication:
'38 Dodge Coupe - Front fender repair. Dents everywhere, cracked corners, and someone used a chisel to try and remove one of the headlights. TIG welded the sheet metal to see if it was easier to hammer weld the seams flat. It was!
'38 Dodge Coupe - Front fender repair. Dents everywhere, cracked corners, and someone used a chisel to try and remove one of the headlights. TIG welded the sheet metal to see if it was easier to hammer weld the seams flat. It was!
Sheet Metal Fabrication:
'38 Dodge Coupe - Making room on the firewall for the lower column mount, brake pedal assembly and master cylinder, and let's not forget fabricating the gear shift assembly!
'38 Dodge Coupe - Making room on the firewall for the lower column mount, brake pedal assembly and master cylinder, and let's not forget fabricating the gear shift assembly!
Sheet Metal Fabrication:
'38 Dodge Coupe - Shortening a column and dashboard from a '53 Dodge Coronet to fit it in the '38
'38 Dodge Coupe - Shortening a column and dashboard from a '53 Dodge Coronet to fit it in the '38
Sheet Metal Fabrication:
'50 Chevy Suburban - I let a few fabricated floor and firewall patches go by without mentioning, but these cowl panels turned out too good, they needed their own category! Just look at the handcrafted channel around the cowl door... Who says gutter work can't be dignified?
'50 Chevy Suburban - I let a few fabricated floor and firewall patches go by without mentioning, but these cowl panels turned out too good, they needed their own category! Just look at the handcrafted channel around the cowl door... Who says gutter work can't be dignified?
Sheet Metal Fabrication:
'38 Dodge Coupe - Custom metal finished tail pan. I don't mean to brag... Well maybe a little.
'38 Dodge Coupe - Custom metal finished tail pan. I don't mean to brag... Well maybe a little.
Sheet Metal Fabrication:
'51 Plymouth Cranbrook - The bottom 6 inches or so of this car had disappeared over the years. Bought rocker panels and fabricated pieces to blend in the bottom of the door pillars.
'51 Plymouth Cranbrook - The bottom 6 inches or so of this car had disappeared over the years. Bought rocker panels and fabricated pieces to blend in the bottom of the door pillars.
Sheet Metal Fabrication:
'64 Ford Falcon - New aluminum radiator, which needed nice custom sheet metal brackets to hold it in place at 90 MPH across the ice road or through the Nevada deserts. I finally cleaned up the wiring a bit, added a fan controller, and painted my new floors.
'64 Ford Falcon - New aluminum radiator, which needed nice custom sheet metal brackets to hold it in place at 90 MPH across the ice road or through the Nevada deserts. I finally cleaned up the wiring a bit, added a fan controller, and painted my new floors.
Sheet Metal Fabrication:
'52 Dodge Power Wagon - Reattached the A pillar to the floor and fabricated pieces to repair what looks like when someone tried to torch cut the front left body mount.
'52 Dodge Power Wagon - Reattached the A pillar to the floor and fabricated pieces to repair what looks like when someone tried to torch cut the front left body mount.
