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Brett's
Aluminum 1941 Willys Coupe |
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(We did not build this car body, chassis or door skins) The project for us is: Build dash, build inner door structure, build structure inside car around doors including reinforced A-Pillars/Hinge mounts, B-Pillars latch assemblies, inner door panels and mount doors. So, lets get to planning and metal shaping!
The belt line on the right side door did not align correctly with the rest of the car. Shape new belt line.
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Cut out preexisting belt line and fit new one in place.
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TIG weld and grind smooth.
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Fabricate flange for garnish molding and correct window channel width of 5/8". Weld in place.
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Build inner door top & window slide channels.
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Install latch assembly
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Do a lot of planning! Then cut out and layout inner door pan pieces for shaping.
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Metal shape inner door pan pieces.
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Fit pieces in place then TIG weld solid and grind smooth. Garnish molding fits great.
Window channel gap is just right!
Window channel gap is just right!
Drill and install window regulators.
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Weld 1/2" thick aluminum on front edge of door, drill then mount hinges.
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TIG weld 1/2" aluminum into A-pillar to create hinge mounts. Then reinforce rest of left and right side A-pillars.
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Mount doors on this Bad To The Bone 41 Willys!
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Shape tail piece, TIG weld in place and grind smooth.
Shape flanges to go around doors.
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Flanges welded in place.
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Time to build the custom dash.
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The profile template and the sheet aluminum. Lets metal shape this into a custom dash!
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Another example or Custom Street Rod fabrication and metal shaping at Street Rods and Classics in Sonora, California!
