Sheet Metal Replacement
I consider these projects in a different category than sheet metal fabrication because I started with factory or reproduction stamped replacement panels.
Sheet Metal Replacement:
'88 Toyota Pickup - My client wanted fender flares and a much stronger front bumper installed on his Toyota pickup. Minimal sheet metal work and some bracket modification for the bumper and this one is back on the road/trails.
'88 Toyota Pickup - My client wanted fender flares and a much stronger front bumper installed on his Toyota pickup. Minimal sheet metal work and some bracket modification for the bumper and this one is back on the road/trails.
Sheet Metal Replacement:
'72 Dodge Dart - Right side quarter panels replaced. A few more finishing jobs to do and then this one is ready.
'72 Dodge Dart - Right side quarter panels replaced. A few more finishing jobs to do and then this one is ready.
Sheet Metal Replacement:
'72 Dodge Dart - Quarter panels are next on the list for the Dart! I fabricated the inner wheel well patches and small rocker patches, but the reproduction quarter panels and trunk floor extensions were bought new. Left side done, on to the right side!
'72 Dodge Dart - Quarter panels are next on the list for the Dart! I fabricated the inner wheel well patches and small rocker patches, but the reproduction quarter panels and trunk floor extensions were bought new. Left side done, on to the right side!
Sheet Metal Replacement:
'77 Cadillac Seville - A '77-'79 Cadillac Seville has a lot of parts that aren't used on any other GM car in production. This includes the fuel tank! When the fuel tank started to leak from rust damage, I had to find a solution. Luckily I talked to the owner of a Cadillac junkyard on the east coast, who told me a Camaro gas tank from the same vintage had a similar shape. The top of the tank (where the fuel gauge and sending unit attach) is different and would have to be modified, as is the filler neck. Overall the two tanks are very similar, which allowed me to cut the top of the old tank off and weld it onto the new tank. The original Cadillac filler neck was removed and soldered in place of the Camaro filler neck. I also had to remove the original fuel pump pickup baffle from the inside bottom of the old tank and solder it into the new tank. I'm glad I found a knowledgeable source before I started this project!
'77 Cadillac Seville - A '77-'79 Cadillac Seville has a lot of parts that aren't used on any other GM car in production. This includes the fuel tank! When the fuel tank started to leak from rust damage, I had to find a solution. Luckily I talked to the owner of a Cadillac junkyard on the east coast, who told me a Camaro gas tank from the same vintage had a similar shape. The top of the tank (where the fuel gauge and sending unit attach) is different and would have to be modified, as is the filler neck. Overall the two tanks are very similar, which allowed me to cut the top of the old tank off and weld it onto the new tank. The original Cadillac filler neck was removed and soldered in place of the Camaro filler neck. I also had to remove the original fuel pump pickup baffle from the inside bottom of the old tank and solder it into the new tank. I'm glad I found a knowledgeable source before I started this project!
Sheet Metal Replacement:
'82 Jeep CJ7 - Metalwork on the Jeep finished and looking good as new. Next on the list is sending it to paint.
'82 Jeep CJ7 - Metalwork on the Jeep finished and looking good as new. Next on the list is sending it to paint.
Sheet Metal Replacement:
'82 Jeep CJ7 - My clients want to have a solid Jeep again, so it's time to replace the rusted metal . New tub sides, and repairs to the floor and uni-body frame rails are underway. The rear of the tub and front fenders will need a little attention as well. I purchased the tub side panels, but I fabricated all the other panels.
'82 Jeep CJ7 - My clients want to have a solid Jeep again, so it's time to replace the rusted metal . New tub sides, and repairs to the floor and uni-body frame rails are underway. The rear of the tub and front fenders will need a little attention as well. I purchased the tub side panels, but I fabricated all the other panels.
Sheet Metal Replacement:
'63 VW Transporter - Unfortunately the bottom of the windshield frame had rusted over the years. The metal was so thin in some places that a utility knife could easily pierce through. New metal took care of that!
'63 VW Transporter - Unfortunately the bottom of the windshield frame had rusted over the years. The metal was so thin in some places that a utility knife could easily pierce through. New metal took care of that!
Sheet Metal Replacement:
'63 VW Transporter - Floor is installed and solid as ever. Soon this project will be ready for the streets again.
'63 VW Transporter - Floor is installed and solid as ever. Soon this project will be ready for the streets again.
Sheet Metal Replacement:
'63 VW Transporter - Both front fenders, or doglegs as VW calls them, have been replaced. The bottoms of both B pillars needed to be replaced as well. Now the door gaps are tolerable and there is enough solid metal to install the floor.
'63 VW Transporter - Both front fenders, or doglegs as VW calls them, have been replaced. The bottoms of both B pillars needed to be replaced as well. Now the door gaps are tolerable and there is enough solid metal to install the floor.
Sheet Metal Replacement:
'63 VW Transporter - The lower nose panel has been replaced, and two new front door skins were installed onto new door frames. This project is looking way more solid already! Up next will be the panels underneath the doors, and then the front floor.
'63 VW Transporter - The lower nose panel has been replaced, and two new front door skins were installed onto new door frames. This project is looking way more solid already! Up next will be the panels underneath the doors, and then the front floor.
Sheet Metal Replacement:
'63 VW Transporter - I started out by replacing the bottom of the A pillars, and the center piece that connects the pillars to the rest of the uni-body frame. Unfortunately I found more rust in the lower part of the nose, so a patch panel was bought for that. Most pictures show that I have no gap between the old and new section of A pillars. I tacked them in place with no gap, then cut the gap wider for a proper weld.
'63 VW Transporter - I started out by replacing the bottom of the A pillars, and the center piece that connects the pillars to the rest of the uni-body frame. Unfortunately I found more rust in the lower part of the nose, so a patch panel was bought for that. Most pictures show that I have no gap between the old and new section of A pillars. I tacked them in place with no gap, then cut the gap wider for a proper weld.
Sheet Metal Replacement:
'63 VW Transporter - As you can see, this cool little VW Transporter was in need of some more solid metal! Luckily the ice was thick enough to bring it over to my shop. This project will entail A pillars, front floors, new doors, and a few other little patches.
'63 VW Transporter - As you can see, this cool little VW Transporter was in need of some more solid metal! Luckily the ice was thick enough to bring it over to my shop. This project will entail A pillars, front floors, new doors, and a few other little patches.
Sheet Metal Replacement:
'69 Chevy Camaro - Rear seat divider installed, rear bumper brackets installed into the trunk, convertible B pillar brackets installed. This thing is looking finished! I welded a few factory gaps closed that would normally have been seam sealed to avoid using filler.
'69 Chevy Camaro - Rear seat divider installed, rear bumper brackets installed into the trunk, convertible B pillar brackets installed. This thing is looking finished! I welded a few factory gaps closed that would normally have been seam sealed to avoid using filler.
Sheet Metal Replacement:
'69 Chevy Camaro - Taking time to do all the little patches that I might have missed during the project. Soon there wont be much left to do but deliver it to paint!
'69 Chevy Camaro - Taking time to do all the little patches that I might have missed during the project. Soon there wont be much left to do but deliver it to paint!
Sheet Metal Replacement:
'69 Chevy Camaro - The floor is in! A major milestone. I was able to raise the jig up off the ground to give myself more room to access the plug welds along the bottom of the floor pan. There was a lot of overhead welding involved, but I'm happy to say the floor is solid as ever and looks good!
'69 Chevy Camaro - The floor is in! A major milestone. I was able to raise the jig up off the ground to give myself more room to access the plug welds along the bottom of the floor pan. There was a lot of overhead welding involved, but I'm happy to say the floor is solid as ever and looks good!
Sheet Metal Replacement:
'69 Chevy Camaro - After a long break from doing things that are cool, I'm happy to be back on the Camaro project! Both toe kick panels have been welded in, and now I am all ready for the floor pan to go in. Early next week I will have the last major component installed. Looking forward to completion!
'69 Chevy Camaro - After a long break from doing things that are cool, I'm happy to be back on the Camaro project! Both toe kick panels have been welded in, and now I am all ready for the floor pan to go in. Early next week I will have the last major component installed. Looking forward to completion!
Sheet Metal Replacement:
'69 Chevy Camaro - Getting the floor fit into place. I welded the under floor braces to the bottom of the pan while it was removed from the car, similar to what I did with the trunk floor. Save the overhead welding for when there is no other option! Need to do some work to the bottom of the firewall before the floor is ready to get welded in, but it is looking good.
'69 Chevy Camaro - Getting the floor fit into place. I welded the under floor braces to the bottom of the pan while it was removed from the car, similar to what I did with the trunk floor. Save the overhead welding for when there is no other option! Need to do some work to the bottom of the firewall before the floor is ready to get welded in, but it is looking good.
Sheet Metal Replacement:
'69 Chevy Camaro - Inner wheel well patches fabricated and welded in. Looking like a lot of new metal!
'69 Chevy Camaro - Inner wheel well patches fabricated and welded in. Looking like a lot of new metal!
Sheet Metal Replacement:
'69 Chevy Camaro - The center floor section had a lot of rust hidden between the layers. I eliminated most of the rot to be able to plug weld the floor section onto the frame rails, but there was still more. It took a lot of little patches, but it is finally solid again. Ready for inner wheel well patches to go in.
'69 Chevy Camaro - The center floor section had a lot of rust hidden between the layers. I eliminated most of the rot to be able to plug weld the floor section onto the frame rails, but there was still more. It took a lot of little patches, but it is finally solid again. Ready for inner wheel well patches to go in.
Sheet Metal Replacement:
'69 Chevy Camaro - Trunk floor is in! After the center floor section was plug welded to the frame rails, I could then line up the trunk pan where it needed to be. Once the trunk pan was located in the car, I marked the location of the braces under the floor and welded them together on the workbench. Much easier than having to do it overhead! It all worked out well, because the braces fit tight to the inner tail pan pieces that I had fabricated a few projects ago.
'69 Chevy Camaro - Trunk floor is in! After the center floor section was plug welded to the frame rails, I could then line up the trunk pan where it needed to be. Once the trunk pan was located in the car, I marked the location of the braces under the floor and welded them together on the workbench. Much easier than having to do it overhead! It all worked out well, because the braces fit tight to the inner tail pan pieces that I had fabricated a few projects ago.
Sheet Metal Replacement:
'69 Chevy Camaro - The center section of the floor between the trunk and the back seats has to be rebuilt. Most of this fabrication will be hidden when the car is complete, but it still needs to be done correctly! The strength of a uni-body car comes from combined layers of sheet metal.
'69 Chevy Camaro - The center section of the floor between the trunk and the back seats has to be rebuilt. Most of this fabrication will be hidden when the car is complete, but it still needs to be done correctly! The strength of a uni-body car comes from combined layers of sheet metal.
Sheet Metal Replacement:
'69 Chevy Camaro - Giving some attention to the lower bumper mount holes. Rust hides in the smallest spaces! Welding the outside panels first so that I can have access to get behind them if I need to. Since the interior panels will remain hidden, they get welded in last to cap it off.
'69 Chevy Camaro - Giving some attention to the lower bumper mount holes. Rust hides in the smallest spaces! Welding the outside panels first so that I can have access to get behind them if I need to. Since the interior panels will remain hidden, they get welded in last to cap it off.
Sheet Metal Replacement:
'69 Chevy Camaro - Rear frame rails are welded in! Lower trunk panels were put in first to allow easy access. The driver's side tail pan had a few rust holes that showed up, so a patch had to be fabricated. I cut access holes into the tail pan to be able to plug weld the inner tail pan to the rear of the frame rails. This Camaro is starting to come together!
'69 Chevy Camaro - Rear frame rails are welded in! Lower trunk panels were put in first to allow easy access. The driver's side tail pan had a few rust holes that showed up, so a patch had to be fabricated. I cut access holes into the tail pan to be able to plug weld the inner tail pan to the rear of the frame rails. This Camaro is starting to come together!
Sheet Metal Replacement:
'69 Chevy Camaro - Slowly uncovering and replacing all the rust in the trunk, wheel well, and quarter panel areas that need it. Much easier to access these spots now with the trunk floor and frame rails removed.
'69 Chevy Camaro - Slowly uncovering and replacing all the rust in the trunk, wheel well, and quarter panel areas that need it. Much easier to access these spots now with the trunk floor and frame rails removed.
Sheet Metal Replacement:
'69 Chevy Camaro - Making lots of empty space in this Camaro! Removed the trunk floor and rear frame rails to have access to the inner trunk pieces, and any other rot I find along the way. Now is the time to get it out of there!
'69 Chevy Camaro - Making lots of empty space in this Camaro! Removed the trunk floor and rear frame rails to have access to the inner trunk pieces, and any other rot I find along the way. Now is the time to get it out of there!
Sheet Metal Replacement:
'69 Chevy Camaro - Rocker panels are plug welded in, and tacked under the dash. Lots of little patch panels went into making solid metal for the rockers to attach. Next I will move into the trunk area and replace the rear frame rails before the new floor pan gets installed.
'69 Chevy Camaro - Rocker panels are plug welded in, and tacked under the dash. Lots of little patch panels went into making solid metal for the rockers to attach. Next I will move into the trunk area and replace the rear frame rails before the new floor pan gets installed.
Sheet Metal Replacement:
'69 Chevy Camaro - On the jig and underway! Temporary bracing installed to keep the car from folding in half, since there is no roof to hold it together. No turning back on the project now!
'69 Chevy Camaro - On the jig and underway! Temporary bracing installed to keep the car from folding in half, since there is no roof to hold it together. No turning back on the project now!
Sheet Metal Replacement:
'69 Chevy Camaro - Full floor and trunk pan and frame rails coming soon! This project is just getting started since we finally had a thick enough ice road to bring it to the shop!
'69 Chevy Camaro - Full floor and trunk pan and frame rails coming soon! This project is just getting started since we finally had a thick enough ice road to bring it to the shop!
Sheet Metal Replacement:
'50 Chevy Suburban - After all the metal replaced in the cab floor, the rusty door bottoms looked out of place! No longer an issue.
'50 Chevy Suburban - After all the metal replaced in the cab floor, the rusty door bottoms looked out of place! No longer an issue.
Sheet Metal Replacement:
'50 Chevy Suburban - New inner fenders and mounted the freshly rebuilt outer fenders onto the front of the Suburban. Its starting to look complete now, but just wait until the shiny new chrome grill and bumper get attached!
'50 Chevy Suburban - New inner fenders and mounted the freshly rebuilt outer fenders onto the front of the Suburban. Its starting to look complete now, but just wait until the shiny new chrome grill and bumper get attached!
Sheet Metal Replacement:
'38 Dodge Coupe - Unfortunately the hood I plan to use had cracked along one of the seams. I practiced my TIG welding on sheet metal some more and made it look nice again!
'38 Dodge Coupe - Unfortunately the hood I plan to use had cracked along one of the seams. I practiced my TIG welding on sheet metal some more and made it look nice again!
Sheet Metal Replacement:
'50 Chevy Suburban - Bottom of both A and both B pillars replaced, rocker panels replaced, front body mounts replaced, floor done, door hinges rebuilt, firewall patched, this one is just about ready for summer cruising!
'50 Chevy Suburban - Bottom of both A and both B pillars replaced, rocker panels replaced, front body mounts replaced, floor done, door hinges rebuilt, firewall patched, this one is just about ready for summer cruising!
Sheet Metal Replacement:
'68 Ford Bronco - Left quarter panel replaced due to collision, front clip replaced, cowl panels replaced and strengthened attaching surface for stainless steel windshield hinge.
'68 Ford Bronco - Left quarter panel replaced due to collision, front clip replaced, cowl panels replaced and strengthened attaching surface for stainless steel windshield hinge.
Sheet Metal Replacement:
'71 Ford Race Courier - Cut off the Mazda front clip a previous race team had installed and went back to a Ford front clip.
'71 Ford Race Courier - Cut off the Mazda front clip a previous race team had installed and went back to a Ford front clip.
