1940 120 Convertible Coupe Restoration

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:40 am

I started restoring this '40 Convertible Coupe for a customer a few weeks ago at our shop. I don't know much about these cars so I wanted to find a Packard forum for when I need help. We'll be completing the restoration; the owner has already restored/rebuilt the drivetrain, frame, and suspension. It needs a ton of metal work before we can start any bodywork. I started a build topic for it on my "home forum" 67-72chevytrucks.com in the off topic section so I'll import those posts to catch up to the current work.

This is it as it was delivered, we have the rest of the parts in storage. The owner was a helicopter mechanic and is very detail oriented so all of the parts were boxed meticulously; each box is labeled with a list of parts and hardware inside.


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User avatar
theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:41 am

Pics of the rust. There won't be much original Packard metal in the lower 8" once we're done.

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Trunk area.

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Bondo check... used my 3" grinder to get to bare metal around the bottom edge. Lots of filler over caved in metal, and there are gobs of brass showing around all the "patches".

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Old floor "repair" with aluminum pop riveted over the original rusty floors. The rivets had fallen out long ago.

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:42 am

I made body braces out of 1x1 tubing with turnbuckles welded in so I can adjust the door gaps before everything it welded back in. Some of the body mounts are completely rusted away so it's doubtful that the body is still sitting squarely on the frame. This will also keep the body from folding in half once it's on the rotisserie.

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:43 am

Started digging into the driver side lower cowl, rocker area, and lower quarter panel. It was tough to find the rocker seams in the door jamb since they were butt-welded from the factory. I took everything apart the way it was assembled so I could use the original parts for templates. I'll leave the other side together for reference until the driver side is back together.


The cowl was pretty rough, had stress cracks all over it plus rust at the bottom. Cut it out to get to the inner layers.

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Made a paper template before cutting it out.

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Inner door post.

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Inner panel rust.

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Starting on the rockers. Tons of lead and filler.


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Trying to find the rear rocker and quarter panel seam.

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:44 am

Cutting out the quarter panel.

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B pillar post base.

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Removing the outer rocker.

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:45 am

Removing the inner rocker. Had to cut the inner fenderwell back.

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Not much left to go by on the body mount areas.

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Rear half of inner rocker removed.

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Turnbuckle added to adjust height of body.

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Cutting out the front pillar.

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The way the inner brace and sheetmetal were layered made this hard to cut out without doing any damage.

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:46 am

Pillar and inner brace cut out.

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Cutting out the toe board.

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Front half of inner rocker removed.

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Car is now halfway rust free!! :lol: That was the easy part.

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Body brace/mount under the rear seat.

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Made a template of 1/2 of the inner rocker.

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theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:46 am

Pattern made for the rear half of the inner rocker.

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Inner A-pillar support was straightened, repaired, and blasted.

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Making a new A-pillar skin.

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Making patterns for a new B-pillar bottom.

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Made the part in three pieces. It still needs two more pieces on the front half.

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Rear pieces welded in and smoothed.

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User avatar
theastronaut
Posts: 93
Joined: Wed Sep 10, 2014 9:04 am
Location: Anderson SC

Re: 1940 120 Convertible Coupe Restoration

Post by theastronaut » Wed Sep 10, 2014 9:49 am

Made the driver side kick panel patch.

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The cowl vent was rusty so I cut it out.

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Blasted a spot so I could match up the mesh with new stainless mesh from McMaster Carr.

10 openings per inch.

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.020" wire size.

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.082" openings.

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McMaster didn't have the exact mesh size but it'll be close enough that nobody will notice.

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