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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!
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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!
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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.
Mount doors on this Bad To The Bone 41 Willys!

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​Shape tail piece, TIG weld in place and grind smooth.
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​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!
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