READY FOR PRIMER

It has taken more time than I thought to prepare the body for primer.  Initially, I was confident that the gray paint could merely be sanded with 40 grit paper and primed.  However, if you recall, the gray paint began to "flake" as it was being sanded.  Therefore it was necessary to remove it entirely.  If that was not time consuming enough, we discovered some previous body damage that required the installation of a patch panel.

The removal of the gray paint is now complete and the patch panel has been installed, filled and sanded.  We are now ready for primer.  

Tomorrow morning Morris will be moved to the spray booth and cleaned several times with metal cleaner.  Three medium coats of polyester primer will be applied and the body work and blocking will begin Monday.

The next time you see Morris, he will be one color instead of five.

Can't wait...

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843.338.2253

PATCH PANEL BODY WORK COMPLETED

Previously, we discussed the installation of the patch panel.  Today, I completed the bodywork.

As pictured in the photo to the left, I fabricated a plywood template using the undamaged panel on the other side of the car.  The template is wedged in place by three 1"x 1" wood strips  and the filler is then applied using the template as a guide.

Fill and sand, fill and sand, fill and sand and fill and sand...until you get it right.  I sprayed primer on the repaired areas to make sure the bodywork was satisfactory.  Now the body exterior is prepared for the application of the polyester primer.  

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843.338.2253

BODYWORK AT PATCH PANEL

Cutting, fitting and securing a patch panel is only part of the process.  After the initial coats of primer are applied to the patch panel and surrounding areas, the primer should be given ample time to cure.  When properly cured the primer should sand easily without clogging the 40 grit sandpaper.  

In the photo to the left, you will notice that I am applying filler to the  door first.  The door sustained only minimal damage.  After it is repaired, I will use that surface as a guide to contour the patch panel area.  

Also you will notice the adjacent areas have been masked to reduce the size of the work area.  

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843.338.2253

PATCH PANEL INSTALLED

Now that the opening for the patch panel has been prepared and the adjacent latch post has been aligned, we are ready to fit the new panel.

First, I clamped the panel in place and sized it by marking it from the inside. I cut the panel  1/2 inch larger.  This left the correct overlap.

The panel was then set in place with 3M Panel Bond and temporarily held in place with sheet metal screws around the perimeter.  The adhesive was allowed to cure over night and I removed the screws this morning.  The excess adhesive was ground flush with the patch panel and the surface was sanded with 80 grit paper.  The panel and adjoining surfaces were cleaned thoroughly with metal cleaner.

Finally, the damaged areas were primed with epoxy primer in preparation for the application of a minimal amount of body filler.  As you can see in the photo to the right, the panel is in its original position. After the body work is completed, the damage will be undetectable.

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843.338.2253

ENGINE BUILDING CONTINUES

Paul and Ron were in the shop today to continue work on the 1275 cc engine.  The machine work has been completed and all the engine parts have been prepped for assembly.  Today we began the assembly.  Pictured to the left is, from left to right, Paul, me (Tom) and Ron.  Paul and Ron are expert engine builders that have retired from the trade.  They help us from time to time and their expertise is greatly appreciated.  We enjoy their stories and humor.

Today, the new freeze plugs, camshaft, crankshaft, timing gear assembly and seals were fitted.  Then the block was mounted on the engine stand in preparation of final assembly.  The pistons and cylinder head will be installed next.

Bill and I were otherwise occupied.  We were installing new rubber seals on the vent windows and window track felts on the operating windows. The surgeon, in the photo to the right, is Bill.  He is installing the new track felts.  Now, both operating windows are ready to install.

Stay tuned...
Tom McCurry
Tommy's Topless Cars
tommystoplesscars@yahoo.com
843-338-2253

GOOD NEWS...BAD NEWS

The good news is; with the new porta power I purchased, I pushed the driver's door post back into position.  Now the new patch panel can be installed.

The bad news; as I began to trim the patch panel, my air compressor died.  So now, without compressed air in the shop, fitting the panel will be a bit more difficult.  

Mondays...

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843.338.2253

BODYWORK CONTINUES

There is one more obstacle to be overcome before the patch panel can be set in place.  The driver's door latch post was pushed inboard during a collision some years ago.  In order to repair the damage properly, a hydraulic porta power must be used to gently reposition the post.  The latch panel itself has been heated and straightened.  However, it must be moved in an outboard direction approximately 3/8".
While attempting to move the panel, the ram section of our porta power ruptured.  It's annoying to say the least, but, things happen.  I purchased another one this morning so we will be good to go Monday morning.






Stay tuned...
Tom McCurry
Tommy's Topless Cars
tommystoplesscars@yahoo.com
843-338-2253

SANDING ALMOST COMPLETE

 As we discussed in a previous post, it was necessary to remove the gray paint because it was flaking.  The green paint, however, is very stable.

The only remaining gray paint is on the roof.  Next the entire car will be "scuffed" with an 80 grit block to remove any places we may have missed.

We are almost ready for primer.

Can't wait...

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843-338-2253

PATCH PANEL INSTALLATION

As we discussed previously, the installation of a patch panel behind the driver's door was necessary due to a poorly done body repair from years ago.  

After the damaged sheet metal was removed, the edge of the opening was crimped with a special tool that creates an offset as shown in the photograph to the left.  Now the patch panel can be fixed to the opening and the face of both panels will be flush.  Very little filler will be required.

The latch jamb for the driver's door, shown in the photo to the right, was also crushed.  I straightened it by heating the area with a torch and moving it back into position with the use of a slide hammer.  The jamb must still be moved approximately 3/8" in the outboard direction.  This will be done with a hydraulic porta power.  At that point, the patch panel can be installed.

I love this car...

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843-338-2253

A BUSY DAY AT THE SHOP

Our engine builders, Paul and Ron, were in the shop today preparing the engine for final assembly.  All the components have been cleaned, lubricated and fitted.  The final shipment of parts is due tomorrow morning.  

 Yesterday, Bill and I had the bumper and grille parts sandblasted.  Today, I applied two coats of self-etching primer and began straightening the damaged areas.

 We also sandblasted the transmission tunnel.  It is in amazing condition.  I applied primer to both sides and an additional coat of the rubberized undercoating underneath. The topside will receive a final coat of green urethane to match the interior.  We plan to install a mat on the floor pan designed to reduce the temperature and road noise in the interior.

We welcome our followers from the UK, Canada, France and Australia.

Stay tuned...

Tom McCurry

Tommy's Topless Cars

tommystoplesscars@yahoo.com

843-338-2253