The Stovebolt Site Forums Project Journals Archived Journals 1940 Chev 1/2 ton “Franken/Restomod”

Good morning Everyone;

As always, thank-you for checking in and following along.

I was a good citizen and got my annual flu shot, I felt like crap for the next 2 days and then I promptly got sick. The dreaded "Man Cold", I know, I know, pretty serious but I am pulling through and getting better! Thanks for your concern.

Anyways, I got the front splash aprons 90% complete on this round of work. Starting with a cardboard template I quickly found out how much difference there is side to side. Pulling the bumper out here and pushing the fender in there...
Those adjustments helped, but I still needed to make a separate template for each side rather than one I could flip over depending on the side being worked on. I couldn't see the differences with the naked eye and measuring at key points it was within 1/16" but when you laid the template in there it just didn't fit the same.
Once I had the cardboard templates made I copied them on to construction paper and them outlined them with some 1/2" wide tape. Once those were cut out, I then traced that outline on some 18 ga sheet steel and proceeded to cut that out. Some sanding was required to smooth the edges so that no imperfections were transferred to the piece when the edges were rolled over. Once I had the blanks made, I guesstimated where I wanted the raised edge to be, using some clear plastic sheet taped over the blank I traced, cut and then transferred that shape to plywood. The plywood edges needed to be sanded smooth as it would be the guide used when running the piece through the Pull-max and would transfer any imperfections to the raised edge. The 1/2" tape was to allow extra material for the edges which were rolled over last, again using the Pull-max. There is a pivoting shoe and adjustable depth which rolled the edge over 90 deg in 4 or 5 passes through. It turned out pretty good, except for the outer edges as that radius was about 2" and was too tight a curve for the steel to form smoothly. To get it right after I needed to make some zip cuts in the edges and hammer the edges smooth, etc.

It took me about 4 hours to make the templates and what-not, but only took about 1 hour to form the raised lip and roll the edges over. The remaining time was spent on hammer and dolly work, trimming and fitting the pieces as needed to final shape. Welding, grinding and sanding as needed. Total time to get to where I am is about 25 hours. I still need to build the hold down tabs and determine where the fog lamps should be placed. Adding some extra support where they are mounted will need to be done as well. Probably another 3 or so hours is needed.

I am very pleased at how it turned out, once painted and the vintage fog lamps are installed it will really come together.

I did take some pictures, they are attached as usual.
That is all for now,
Steve