THE MIRACLE
OF GETTING
A CHANCE
TO REBUILD
MY CAR
AGAIN, 20 YEARS LATER
Eric
Gordon's 1954 Kaiser
Convertible
Conversion
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ERIC
GORDON'S '54 KAISER CONVERTIBLE
APPROVED
BY DESIGNER "DUTCH" DARRIN
| On my nineteenth birthday
I bought a used '54 Kaiser Manhattan right off a
New Jersey automobile dealership's showroom floor. Originally this car was a 2 door Sedan. And I made it....converted it to a "Convertible" (vin # K542-002380). Yes, I just started with a hacksaw,
pliers, chisel, hammer and screwdrivers.
At that time my family lived
in an apartment and our cars were parked in city streets.
OH ! Kaiser designer Howard "Dutch" Darrin's approval ? Once I finished building the
Convertible, I volunteered for the U.S. Air Force, and was
"Mr.Darrin, I did it...I am the
"redesign... ahh...reworker," I answered.
He then invited me and my friends
to his house. I parked in his driveway. I listened
Next to my car, in his driveway,
was a new Volvo which he was at that very moment in the
Reflecting upon this decades
later, I realize I truly was in the presence of one of
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This is how Eric built the 54 Kaiser Convertible. It's now time to look at how he found that car after some 20 odd years of searching. |
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That was about 3 decades ago. Today Eric was fortunate enough to get a second chance to rebuild his convertible. |
c
copyright 2005 by Aigle Books
POST SCRIPT:
ERIC GORDON, Writer, Editor, Publisher of
Aigle Books, Place ST. Georges, Paris, France GIVES HEREBY
PERMISSION: for John MacDonald- "Sympatico
Mail" <johnmd1@ns.sympatico.ca> and ,sharon@summerville-
novascotia.com. to use my writings, computer
sending and pictures for the above named internet pages.
(Saturday 26 March 2005.)
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For
family reasons Eric had to trade this car for an airline ticket back East,
Surprisingly, it is only 99.9
miles from the New Jersey driveway where
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The following announcement was received from Eric Gordon on the 28th of April 2006. <> NEWS <> CONVERTIBLE NEWS <> DRIVING TO PENNA
/ RENT U-HAUL
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And now the story continues
Early in the morning of April 29'th Eric took a little drive to Pennsylvania.
The following pictures will tell the story of the start of a new life for
"ERIC GORDON'S '54 KAISER CONVERTIBLE"
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some three decades ago... |
I built/rebuilt some 30 years ago.... |
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So my machine must now be on it's own, for a while...
I take this very personal...
I then settled down to brass, aluminum and copper tacks
and started restoration.
Now,
My convertible is only seven miles away, awaiting a
space on the new lift.
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work to be done on my convertible was the way to go. |
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My convertible gets a piggy-back to Craig's garage
for a break job and a tune up.
I had already bought the many parts needed at various auto "swap-meets" and car shows. |
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It's been a long winter waiting for this day to come |
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...the very same where my 4 door (see Kaiser Manhattan
Rebuild) in www.kaiserfrazer.ca
got a new drive-train and paint |
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Back in the 50's the previous owner's father used
to operate a Kaiser Frazer dealership out of this shop
and showroom. |
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CRAIG'S GARAGE
Craig, is now the new owner and shares my enthusiasm of having found my convertible again... |
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The paint booth is visible in the back, doors wide
open!
Now my convertible... |
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...is awaiting PHASE II of this restoration. |
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Back in the 50's this was actually a Kaiser Frazer dealership. |
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A place on the lift and work starts... |
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The first thing is removing the gas lines and then
the brake lines. |
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Craig is now ready to start the brake replacement |
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... as well as a new brake-master-cylinder, visible here, which Kaiser Motors must have subcontracted from the Ford Motor Company which used this exact type of master cylinder on their '49 thru '51 Ford & Lincoln automobiles. |
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All new brake calipers and new brake shoes
are to be installed ........ |
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...... along with new brake lines.... |
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.....and flexible hoses |
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The gas tank was completely cleaned out of the
heavy/old/slushy gas and, a new plug installed; next : new gas lines. |
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Both standard stainless steel fuel lines... |
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...and hi-tech modern neoprene lined fuel injection flexible plastic hose is used. |
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New sparkplugs installed, |
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... and now distributor points... |
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..delivering parts in my 4 door 1954 Kaiser Manhattan : |
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"Standard" brand distributor cap... |
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A brand new 6 volt battery was purchased,
and it has a familiar "back-then" look. |
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... now points-rotor-cap are all new, then, new gas
was added a new filter to the pump and the engine started right up.
It has a very low, deep muffled sound, very steady! {Now a gallon of gas is $3.08 regular, and this car drove over 300 miles from Las Vegas to Hollywood, at one time, on only $1.50 worth of gas.} |
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High and dry, my convertible is waiting for some minor mechanical work. |
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The work that Craig was doing is finished and the Convertible is..... |
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back home where it was driven a bit in the driveway.
Something that it hadn't done for many years. |
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.."ancient " 14 inch bias tires (left) are at
least 25 years old, and can now finally be replaced with new
15 " spoke wheels with new radial tires (center). |
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..while a 15 " steel wheel will get a new radial tire
also
and be used as a spare; meanwhile ... |
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...15" spoke wheels are installed with new radial tires... |
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...including sporty center hubcaps ! |
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Besides new tires, my convertible also has missing
parts that need restoration work, such as this '52 Buick vent window handle.
(Original conversion I used Cadillac and Buick window parts.) Vent window handle is still available at... |
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...Kleeman's Salvage, and can be bought at a reasonable price. |
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Another item bought at Kleeman's is this missing section >shown on right< of the driver's side door frame. It is cleaned with "Naval Jelly" - a rust inhibitor - |
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...to prevent future rust formation;
and sanded smooth many times. |
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Then, this partial frame > left< gets a first application of undercoat paint, then... |
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...placed on door with existing frame for exact millimeter fit. The ... |
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... TWO door frame pieces are pressed, 'plyered' and hammered, actually: "metal sculptured," into ONE usable door frame ; and the very first coat ... |
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... of bondo, a "body filler" metal to metal plastic fastener, when dried becomes very hard, yet "sculptural ability " is applied. |
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After 5 sanding and "bondoing" > a grey, spoon size chemical in center of photo gets mixed with a drop of hardening chemical - in tube <and applied to door frame with a self-made plastic spatula -center left - |
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.. and the TWO pieces become ONE door frame... |
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... with much sanding... |
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... and sculpturing.
Now ready for several applications of ... |
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...red undercoat paint. And when this dries, door frame gets sanded slightly with "600" wet sandpaper... |
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and the final paint is applied to frame.
>See "Body Work" section for completed installation< |
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And again, my convertible takes a short 10 mile
piggy-back ride on
the same flat-bed truck to... ..and, through the hills of eastern Connecticut, to... |
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..."Carlson Auto"
Now working to restore and paint, ~including welding
and general repair ~ if needed.
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...door jams, dash, underside of hood and trunk lid,
undercarriage
and repair of body panels as necessary. Chief mechanic/body-specialist Mark is on right, while I am helping out with starting fluid on left. (Son Matthew took this photo). |
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Carlson Auto's completed works speak volumes;
such as this customer's '56 Chevy soon ready to "rock 'n roll"... |
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... while my convertible and the car on right will now get restored ... |
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Mark Carlson is taking on the challenging task of supervising the subletting/outsourcing of all the re-chroming... |
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...he knows just where to have this bumped,
battered and beaten up old chrome.... |
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...repaired, and totally refurbished with " NewChrome ." |
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However, in order to get to this stage of the restoration?
The NuChrome workshop knows, with... |
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... "chroming" it is an exact science, which must be carefully restored/balanced with lethal chemicals and electricity... |
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....sparks flying,
the chroming technician also becomes a molding-shaping-straightening "metal~artist"... |
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...and a "heavy-metal sculpturer" !
So, Mark carefully unwraps the finished items from NuChrome, and... |
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...he explains while showing me the first chromed
bumper parts : " this 'triple chrome' means first copper, then nickle, then chrome, not chromed three times..." |
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since I have a "1953 Lincoln" front bumper which does
not have the indentation of the Kaiser rear 'bullet bumper guard'
...he had the chrome shop "artistically craft" the same indentation here (shown on right)...to match the rear of the Kaiser design (left). |
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Originally I had selected this '53 Lincoln
front bumper since it has
the "bullet" shaped bumperettes, similar to the Kaiser rear bumper... plus, Lincoln bumper follows the contour of the Kaiser splash~panel below the '54 massive grill ! (It has been 55 years since this bumper "wore" new chrome.) |
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The chrome shop marks each chromed item
with an "in-shop number"... |
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Mark Carlson further supervises the removal of blemishes, dings, pot marks and welding needs, as pointed out here on the inside of bumper (center of photo). |
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My initial reaction : ... "stunning" should be in
an Art Gallery !
This photo inspires me to start my very own Art Gallery called : "GGG" ~Gordon Garage Gallery ~ in my Daytona Beach home garage |
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...yes, the rear bumper (top)... |
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and the rear " bumper~cradle " would make a
great,
shiny sculpture in an Art Gallery ! |
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The 5 piece front grill, 2 piece hood scoop
and headlight trim is next... |
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"I drove the convertible in the "Carlson Auto"
driveway..' superb handling,with the new brakes and new exhaust
system as quiet as a Rolls Royce !
Next....the front chrome gets removed.. |
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..while the car is raised somewhat... |
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.. Mark and Matthew Carlson are removing the... |
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... massive and very intricate "inward-bowed" grill. |
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Even I help, by removing the distinctive early
50's
Buick look alike, 1954/55 Kaiser headlight frames. Some automobilists like to call them "doors." |
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"DE-CONSTRUCTION"... |
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...is NOT a very pretty sight . |
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Tail lights hood-scoop and door handles also
get removed,
ready for chroming. All other shiny surfaces, windshield and side window treatment, including the 6 inch strip on bottom of doors and fenders, are famous " Kaiser~Industries~Stainless~Steel " and will only need some polishing. |
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...disassembly continues, I even helped removing most of the interior, because .... |
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...the frame will be box welded for added strength.
Any inside lines (brake and fuel), shown here, will be moved to the outside of the frame. |
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...restoration also includes new rocker panels
Mark is also an expert welder. |
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Paint removal is definitely messy... |
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... necessary... |
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...job. Body prep is utmost important. |
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Mark of CARLSON AUTO said:
"...I felt more like an archaeologist digging though the layers of paint and body filler. To me it's like unwrapping it.... not quite knowing what you find." |
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... "boot", trunk lid prepped for undercoating... |
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...now the hood ! |
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..."Bonnet" as the English~English would say. |
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..."Bonnet" as the English~English would say. |
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Including the large front "splash panel"
54-55 Manhattans have a 3 piece unit, prevalent in the earlier classics, which has totally disappeared on modern cars. |
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Hood, ready for undercoating |
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And naturally...
...the convertible's main body, doors and fenders, get the CARLSON AUTO thorough body preparation treatment, waiting for the special undercoat paint. |
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CARLSON AUTO also built a clever storage shelter...
.. just for my various disassembled convertible parts...
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wating for their turn of reassembly. |
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After rocker panels and fenders are removed... |
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.... some frame areas ... |
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... need to be strenthened and... |
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... and in some areas requires heavy metal welding.
( Deconstruction " frame on ~ frame off " is not a pretty site). |
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Mark is testing new front seats for proper mounts. |
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Four light blue metallic paint samples are picked.
At first?.... in the can, they all look the same. |
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Then, four metal plates are painted. |
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And when new paint samples are dry, they take on quite an individual " metallic blue", and then are... |
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... placed on a portable cardboard that I can take
around with me in different shades of light, night and day. |
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Meanwhile, Mark is measuring " half rounds "
for portions of metal that might... |
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... be needed to support and strengthen the
"customized" wheel wells. |
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Driver's side door frame needs rebuilding. |
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...piece by piece ... |
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...of front brace of door frame. |
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..actually total "re-sculpture" of entire door frame. |
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Close-up of door hinge receiver plate |
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...some frame members need to be fabricated... |
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....and welded to "good" frame... |
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some replacement material is manufactured
outright,
such as .... |
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... these totally new lift points, super strengthening
the frame, which Mark Carlson designed for
future service needed. |
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...also body supports, |
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new rocker "backer" and sill supports! |
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Better than "FACTORY" sill supports. |
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Mark said: " I feel that the structure of the
car
needs to be sound, before ... more cosmetic work begins... |
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...entire sections of rusted floor metal are cut out,
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and new floor metal welded in |
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Matthew prepares floor metal for welding, he
is
standing where entire new floor braces and floor metal will be welded in. |
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Carlson Auto's strong point... |
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is to "metal~sculpture" first ... |
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and then weld in new floor sections.
Some after market floor-pans are used, |
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however, most metal sections are designed,
imagineered~immediately, right on the spot. |
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this procedure is repeated ... |
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...on the driver's side... |
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... rebuilding the metal floor. |
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also where needed... |
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new metal is designed and welded into place. |
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Welding sparks are flying, as new... |
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... metal is placed over some of the existing u-shape frame... |
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...measured here exactly by Mathew,
then welded into a new box frame. |
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... rusted metal is replaced |
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where needed, and |
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steel support bars are inserted into frame wherever weakness is found. |
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while DAN an auto-body helper, |
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of the CARLSON AUTO team, is applying the
standard gray undercoating, RTV adhesive sealant, |
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and then black rustoleum spray paint. |
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...rear axle is removed, cleaned ... |
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... also sludge removed and gears inspected... |
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... Matthew is applying undercoating... |
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...new undercoating applied... |
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...then painted... |
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while sagging rear leaf springs (left)
are replaced with new ... |
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... and then, new leaf springs,
and restored rear axle are reinstalled. |
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...gas tank is also removed... |
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...and sludge is found... |
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...including a completely emulsified
inner tank gasoline filter.. |
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Mark mentioned more than once "feeling like
an automotive archeologist" as this fuel-sensor-probe
clearly shows... |
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including a small connecting gas tank hose.. |
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through the "Kaiser Store" in Arizona
I purchased a re-manufactured fuel sensor. |
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...now, easy access to rear fender panels. |
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New sheet metal is welded into place |
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rusted metal removed and body panels "re-sculptured" |
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...there was some serious
rust damage on the
bottom of the front fenders, in the seam area forward of the wheel wells... |
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...all has been cut out and new steel welded in. |
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Old undercoating was scraped out of fender's underside. |
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Large portions were cracking loose thus allowing dirt
and moisture behind it.These were cleaned and rust treated by applying new rubberized undercoating... |
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Mark Carlson is using these "half rounds"to fabricate.. |
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...cut: weld.... |
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....cut; weld; and re-engineer new rear..... |
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...rear wheel wells. |
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actually "imagineering" new
wheel wells.
And then undercoat, and... |
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...... undercoat paint , while axle and
wheels are still removed. |
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New " imagineered " rear wheel wells:
Driver's side top left, passenger side: right. |
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Mark continues:
" The material on trunk & hood is a polyester body filler~ like bondo. It is a thin sprayable kind that is applied through a special spray gun. |
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.And...when dry, I block sand the part.
Any large imperfections are taken out with a hammer and dolly...after the panel is perfect I will apply urethane primer." |
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Meanwhile in April 2009 (3rd year of restoration)
the chrome came back all shiny and new, carefully wrapped and labeled... |
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...this includes the huge, finned taillight chrome... |
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...headlight frames and outside door handles... |
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...great care was given to smaller pieces
like this instrument cluster chrome frame... |
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...radio frame and horn button... |
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...the "avionic style" 2 piece hood scoop... |
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... and the distinctive '54 Kaiser front showpiece,
the five unit massive grill. |
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paper thin metal around ... |
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...gas tank filler area was totally removed, |
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..new support metal "imagineered" |
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new vertical "back-brace" imagineered.... |
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...then piece by piece new metal "sculpture/welded" into place... |
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While some trunk rust~holes are being repaired... |
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back splash panel |
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is being removed... |
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...while other paper thin metal is being replaced... |
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... a rear "back-splash" in excellent shape
is found
and purchased, clear across the country, from an Arizona KaiserFrazerClub member, |
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it is prepared, by grinding off any slight rust areas.... |
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...ready for primer coat and installation. |
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...driver's side.. |
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...and passenger side... |
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...are checked for fender to body and frame alignment. |
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"The first spring flowers celebrate with me
and the Carlson Auto refurbishing crew my convertible's third year of restoration." |
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Emphasizing the detailed needed restoration
such as this, which photographer son
Matthew Carlson is documenting... |
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...the new sheet-metal welding below the fuel
tank filler door by his father Mark... |
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... including the left... |
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... middle rear areas... |
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and right...are repair/welded for a solid
back~splash foundation. |
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...the Kaiser Stainless Steel that runs along
the
bottom was also polished and buffed, to a high gloss. Mark Carlson:..." they are not 100 point show but I do think I could use them for a shaving mirror!" |
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Mark is meticulously hammering... |
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... and removing imperfections that still exist, |
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... with a super-fine file, |
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and then buffed out to mirror like perfection |
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55 years ago Kaiser was the first auto manufacturer
which already had a padded dash for safety reasons. |
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Meanwhile, dash gets completely disassembled
rust removed and prepared for primer undercoat paint |
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...this part of the dash is Kaiser Aluminum,
Kaiser saved 20 pounds in weight by using aluminum for underside of switches~shroud.. |
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... for shroud of instrument cluster.... |
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...including radio speaker cover (middle)
and glove box dash-frame. Aluminum requires extra care to remove 3 layers of old paint, before painting undercoat. |
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Meanwhile, the chrome and polish shop
returned the refurbished and polishedKaiser Stainless Steel,
that trims the... |
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... side windows (right), and
the wide bottom line
side-trim (left). |
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Carlson Auto team welds four seat-studs directly
into the floor for easy bucket seat installation. |
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'52 Buick arm~rests/door~handles that need
attention, are... |
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...also repaired with the "right, sensitive touch"
and leather-type vinyl by Jackie, a Lady's upholstery skills, who is also part of the Carlson Auto team. |
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She also redesigned very slim vinyl sunvisors |
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this extreme close up shows her talent for
exactness and attention to detail, for these "mock" pleats. Sunvisors need to stay slim for proper fit. |
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Meanwhile...
new front bucket seat anchor frames are sanded, then rustoleum; ready for pleated vinyl custom seat upholstery. |
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Vent windows are carefully removed.... |
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....ready for chroming. |
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Kaiser has an intricate aluminum dash.
Meticulous care is taken to remove..... |
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....any miniscule spots of old paint, before... |
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...Mark paints primer,
on both sides of the many dash parts, |
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And then 24 hours later.... |
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The primer is dry. |
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Finally, hurray, an important day has arrived,
as Mark mixes the paint, |
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and the first coats of the actual final paint " Lt Montana Sky Blue Metallic" 1994-95 Cadillac, is applied. |
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Like all colors... |
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...they take on different hues in various light. |
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THIS IS IT ... there is no turning back now for another selection of paint! |
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Mark calls the down-position convertible top cover a bonnet. At a local "friendly" salvage yard, Mark finds an 82 Saab's roof, perfect for .... |
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... his "imagineering" project: The right kind of
steel
18 or 20. the proper curvature, no rust, even painted on the roof's underside... I help by wedging a bar to lift the roof slightly, while Mark is sawing the roof 's outline |
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This Saab roof will become the "bonnet" cover. |
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Back at Carlson Auto, Saab roof is laid sideways. |
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Mark is outlining the steel shape. |
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"While I point to the "Bonnet Project." |
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Magic Lady Jackie is asked by Carlson Auto to turn this... |
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...into some very outstanding, comfortable, and
good looking seats. |
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Jackie and Mark are trying out... |
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... how the upholstery will look and fit... |
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I give it the ..."perfect fit A-OK"
while I am pointing to the Kaiser design smaller padded pleats, on seat's back portion to match the... |
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...smaller pleats of the padded dash. One of Kaiser's 7 safety points! Matthew is holding the painted instrument cluster frame to the dash... |
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...for a trial upholstery "look-see" ... |
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...the basic Kaiser seat design is echoed with this
mid 60's GM makeover.
Special seat brackets were "imagineered" for the Kaiser floor with bolts that are welded into the floor for easy seat installation and removal and proper/level fit. |
Use the links below to continue viewing the various stages of the reconstruction
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Total hits on all the car pages