1940 120 Convertible Coupe Restoration

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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 » Tue Apr 05, 2016 8:50 am

I finished up the rear inner fender section.

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Decided to start making the tail panel next. I had a spare tail panel to use as a pattern but the bottom edge was caved in.

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I roughly straightened it and skimmed/blocked it to get the edge shaped up so the paper template will be accurate.

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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 » Tue Apr 05, 2016 8:50 am

The paper template was pretty simple; there isn't much of a compound curve so the paper pretty much laid flat over the panel. I start by using magnets and tape to hold the paper in place tightly.

You can see the cut out for the bumper bracket marked, along with the edges.

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The upper/outer corners had enough shape that I had to fold over a section so the paper would lay flat.

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Pie cut corners to let the paper bend into the weatherstrip channel.

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Some of the details are easier to add with the paper laying flat on the workbench. I measured the flange in the weatherstrip and added that line to the template with fine line tape.

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The tail panel was flipped so the inner details could be added. Tape was added where there wasn't enough paper.

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Blank cut out after the template was finished.

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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 » Tue Apr 05, 2016 8:51 am

To start the tail panel I started shaping it in the english wheel. I pulled the trunk lid out of storage so I could check the shape with a profile gague and compare it to the tail panel.

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The bottom half of the tail panel I used as a template had a tighter bend starting halfway down so I only made the top half match the decklid. The bottom half was also shaped on the english wheel but I used a inner tube over the top wheel so it only rolled the metal in one direction instead of stretching the metal in two directions. I already had enough shape from side to side; the soft inner tube kept the e-wheel from stretching the metal and only added a tighter bend top to bottom.

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With the overall shape finished, I tipped the top edge on the bead roller, starting with the lower edge first. I fine-tuned the edge with a hammer and t-post dolly in the vice, then stretched/shrunk the edge to match the shape of the trunk lid edge. With that edge shaped I tipped the second edge and finished folding it over with a hammer and dolly.

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Added the offsets for the overlappng flanges on the bead roller.

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The bottom edge was the same process as the top, tip/hammer/shrink/stretch to match the original shape. The second edge folded the opposite direction as the top, so I taped a shim to a heel dolly to make it the correct height, then folded the metal over against the dolly.

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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 » Mon Apr 11, 2016 4:01 am

Started cutting out the tail panel and trunk floor. The tail panel had been hit on the left side and poorly patched. They never even straightened the trunk floor, just left it crumpled. :eek:

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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 » Mon Apr 11, 2016 4:01 am

With the tail panel out I had to work on saving the inner C-channel structure. This piece is made from 16 gauge with a folded lip on one side so it's pretty stiff. The passenger side is in fairly good shape but the driver side is bent pretty badly. I had to dig through all of the bondo and sheet metal that had been brazed in place to get the the spot welds that held the c-channel in place.

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L/R c-channels removed.

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Trunk floor cut out.

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First test fit of the tail panel.

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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 » Mon Apr 11, 2016 6:17 am

I made a quick and ugly t-post dolly to help straighten the c-channel sections.

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Passenger side c-channel straightened:

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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 » Tue Apr 12, 2016 12:23 pm

I started on the filler neck cover while I'm waiting on new bead roller dies to dimple the trunk floor.  They should be here tomorrow.
To start, I made "tucks" in the edge using a set of modified Vice-Grips that MP&C posted about in the Garage/Tool section on 67-72chevytrucks.com awhile back.  Hammering these out will cause the edge to shrink.  The middle was stretched with a mallet and sand bag. 


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First quick pass through the planishing hammer to see the rough shape.  Needs more stretching to raise the top still. 


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Made a pattern to check the shape from the original piece. 


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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 » Tue Apr 12, 2016 12:24 pm

Another round of stretching/plannishing. Getting closer.

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Once the bowl shape was where I wanted it I blacked out the area to fold and scribed an line.

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