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, I have guided this >one-of-a-kind-machinery<
again towards its reawakening, towards a new future...
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. |
Page 2
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...panel adhesive is removed with a scotch brite
wheel which doesn't grind the sheet metal. |
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This repair method is used for the left lower fender... |
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as well as the right fender. |
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Close-up of splash pan... |
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...and right lower fender. |
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This repair method is applied... |
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to backsplash panel... |
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as well as bottom line of fenders. |
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Driver's side new floor panels were previously welded into place... |
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...are now already painted in red primer. |
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passenger door's bottom hinge needed to be reset
with new screws... |
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...while some other door parts needed welding
and grinding. |
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Passenger door is now re-installed. Also the underside
of the floorboard now gets painted by Matthew and David with seamsealer,
then red primer paint sealer...
and finally shutz undercoating. |
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Front hood latch filler panel... |
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is now being prepared... |
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...by Mel who is removing old paint... |
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...and David then uses the scotch brite wheel to smoothen
the panel before primer and undercoat
is applied. |
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Trunk lid is primered and block sanded smooth |
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Kaiser factory specifications called for a rubber grommet to be bolted and stapled to the backsplash within the massive sculptured corner bumpers. |
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Dirt, grit and rain had a tendency to settle there
and
lead to rust and corrosion. |
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Mark is 'imagineering' a plastic template to find the exact dimensions... |
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...while David is positioning the proper bumper angle... |
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...Mark is trying out different temporary templates for the exact measures... |
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...that he will replace with sheet metal welded solid
to the backsplash panel. |
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Mark is already welding the left side of the corner backsplash... |
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...while the right side is "sculptured"... |
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...ground to fit by Matthew, and ... |
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...spot welded onto factory backsplash... |
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...and then completely welded, before primer
and
paint is applied. |
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Underside of car is painted with seamsealer... |
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...primer... |
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and finally 'Shutz' undercoating. |
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3/8th copper-nickel alloy fuel lines will also be installed to replace the old fuel lines. |
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...finishing sanding on latch filler panel... |
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...before primer paint is applied. |
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Front panels... |
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...and trunk lid get final sanding by David and Mark... |
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before primer paint is applied, and hung up to dry. |
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Fender/rocker-panel well area gets new sheet metal... |
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... and then "Shutz" undercoat is applied. |
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Kaiser has large full sheet-metal air intakes on
each side of engine... under the fenders. |
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These air intakes are sanded and painted
with red primer. |
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Headlight housings are prepped, |
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...while some welding is being finished on the trunk area's corners. |
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Now that the backsplash's corner additions are
solidly welded, |
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the preparation for primer paint started by applying
light weight new polyester body filler... |
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...and after body filler is dry, it is block sanded. |
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Here is an interesting way of "block" sanding the round section of backsplash, by using part of a rubber hose as guide for sandpaper. |
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Soon ready for primer paint. |
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Previous 2 door roof attachment area's
metal-foundation, |
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...is reworked and strengthened, |
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...for the 'cradle' of the convertible top's 'imagineered' solid metal cover...(no vinyl/cloth snap on boot) |
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Art Griffin, president of the 'KF Club's Sunshine
Region' helped out with some spare parts from some parts cars parked
in his back yard in nearby
Melbourne, Fl. |
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Carlson Auto needed better hinges for the newly reworked trunk lid. A "counter balanced" trunk-lid was a new idea in the early 50's. Kaiser Motors was the first to install this on their 'later' model 2 and 4 door sedans |
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David is preparing these "new" trunk hinges... |
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...for installation. |
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A Perfect fit ... |
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... for the trunk lid. |
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Meanwhile the front splash-pans are painted
with primer... |
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... and shutz undercoat... |
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...and when dry, the top sides get painted with
98-48472 00(P) Lt Montana Blue Metallic
CODE:20 1994-1995 Cadillac. This matches in modern urethane paint, my first restoration : 1958 Olds Blue Metallic enamel. |
"THE CONVERTIBLE TOP"
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Mark Carlson is "Imagineering" a metal top for
the rear deck area. |
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Carlson Auto is "Imagineering" a metal cover
for the rear deck. |
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A rough cut is prepared... |
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...and placed in the right position... |
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...precise measures are now evaluated... |
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Now exact and precise... |
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cuts are outlined... |
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...this includes bending... |
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...and hammering the sheet-metal into place. |
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Weakened deck area needs to be strengthened... |
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...while some rusted side metal is removed, |
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and new steel added/welded... |
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...including steel bars as foundation for the metal cover. |
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Mark is spot-welding center bar, while assistants
are pressing with gloved hand and an extra long screwdriver both sides into place. A smaller steel bar, already curved, lies on the rear fender to be welded next. |
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Spot-welding ... |
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...continues... |
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...to strengthen rear deck area... |
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While the metal top is "imagineered" the vinyl "Pinpoint
GM White" top arrived from New Jersey
and Long Island. |
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Here it is laid out including padding strips
and foam padding |
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And the rear plastic zippered window.
The underside of the top is beige to match sthe top frame's color and interior wood trim. |
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Steel bars are now... |
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...completely welded onto deck frame. |
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Two steel bars supported by wood are... |
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...aligned side by side, to the underside
of the metal cover. |
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The front contour of metal cover... |
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...is cut to match the curvature of the back seat... |
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...while this steel tube gets welded to the very front
underside of the metal cover...
and this small strip will be hammered "tucked under"... |
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Metal cover is welded to deck, then Mel and Matthew each drill... |
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...through the cover and onto the two parallel steel
support bars...these drill holes in the metal cover then get welded to each steel bar. |
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Matthew then cuts metal cover very precisely
between the parallel steel bars, while Mark is balancing the tensile strength of the two sides. |
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The front part of the metal cover is now removed... |
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...from the rear part of the metal cover... |
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...which is now solidly welded to the trunk deck area... |
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Five steel support bars give strength to welded
rear metal cover {now solid part of deck} and to 2 trunk hinges from a
Chevy Cavalier.
These salvage yard hinges, receive a solid "imagineered" framework (r/l middle)... |
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...these late model hinges, can now pivot... |
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{onto which the front metal cover will be attached}
some 90 degrees straight up from the trunk floor. |
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Cavalier trunk hinges now fold forward and upwards. Five steel support bars strengthen the entire trunk area... |
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...from the "new solid trunk-deck area" to the trunk floor... visible here. |
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Mark now welds fastening braces onto "imagineered" movable front metal cover. |
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...to precisely match the Chevy Cavalier
'former trunk support hinges.' |
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Cover is now fastened to hinges, as seen from rear...
while trunk lid is removed temporarily for easy access. |
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Cover and its new support is seen from front... |
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...and a close-up of cover hinges. |
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Meanwhile, underside of removed trunk lid gets painted. |
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...rough metal cover seen from front... |
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...and side, now in down position. |
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Mark explains, "I also made support bars for the
rear window area. This makes up for the support that was lost from the roof and...wheel wells... |
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... they follow the sweeping curve then hook
through the interior sheet metal at the back... |
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...to tie in....I was able to weld the top of the wheel wells to these support bars also." |
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special anchor hinge plates for the convertible top's frame are manufactured... |
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Rear anchor for convertible top is "imagineered" with
strengthening bars and special plate-hinges
(behind clamps)... |
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...after several attempts, to find the absolute
exact
place, special anchor plates are fully welded... |
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... hinge plates are clamped into exact place... |
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...plates are now spot-welded into exact place... |
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...now fully welded. These "imagineerd" pivot
plates,
with adjustable check bolts keep the convertible top aligned, and from sagging in the middle of the frame. The only other fastening point is now the top of the windshield frame locking mechanism. |
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In order for the "pivot-point-bolts" to operate
exactly copper bushings were manufactured for the rear frame-to-bolt contact. |
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Three additional wide steel "back seat support bars"
were also welded into place, not only for back seat strength, but also for more room once top is folded into the top cradle area. |
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Even I help out with grinding with an air drill,
with various sizes of scotch wheels or wire wheels. |
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Mark and crew: Mel and David, are discussing
door repair work. |
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Totally rusted out sheet metal at bottom
of door is removed. |
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New sheet metal is shaped on a bench-press... |
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...and then hammered into somewhat rounded
shape on an antique 1730's anvil. |
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Mark is explaining the exact restoration
(at times he calls this type of work "resurrection.")... |
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I also see the painted fenders and underside of
the hood for the first time...safe in a storage shed |
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...damaged sheet-metal is refurbished with the "lost-lead-process"... |
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...the area to be renewed is first heated up
(while protective fiberglass cloth >center of photo<) protects other auto-body parts... |
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...then lead is melted over the area... |
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...and smoothened, "sculptured" with a wood dowel
into the desired shape... |
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...once the area has cooled, it is filed into
shape
even more... |
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...metal files... |
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...scotch-brite and wire wheels... |
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... smoothen the desired shape even more... |
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...now the arduous procedure of filling in and block
sanding continues with polyester body filler.
Very often up to 7 to 15 times. |
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The final smoothness is only accomplished with
sandpaper, up to 600 grade, and using only the sensitivity, the feeling of smoothness, with hand and fingers over the sandpaper. A hair thickness, a size of a pinhead, will show up as a major infraction on the final paint. |
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...polyester body filler is a flour like paste,it is applied sparingly in small amounts since it hardens within a few minutes, it is applied with a plastic spatula to imperfections ... |
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...the sheetmetal is fine tuned with many applications
and with much sanding in between. |
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...the car is prepped for primer (grey) paint.
Doors and convertible top bonnet cover are painted separately. |
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...between the primer paint coats there is still an opportunity to correct infractions with body filler and fine tuned sanding. The car cannot be touched on the primer paint since prints will show up on the final paint. |
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I help with small, yet tedious, jobs
such as taping the id plate for the upcoming paint jobs, and... |
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...replace the huge air-ducts...
passenger side fits directly over the heater/fan motor...very few cars have this 5 in size... |
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...I install new clamps also... |
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These are "aftermarket new," this side
supplies air directly to driver... purchased from a Corvette sales store... are used on mid 50's Corvettes. |
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..David wears special face protective shield
for final scotch-brite work on rocker panels. |
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Mrs. Mary Carlson is amazed at the work progress
in just 4 days... |
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Mary likes the way I arranged these various intricate,
yet very rare, fasteners designed to attach Kaiser stainless steel trim. |
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...while waiting for primer to dry, the front cowling
already gets painted. |
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...other jobs I help out with are prepping
bumper steel braces... |
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...underside of front splash pan, which comes
in 3 parts..... |
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...buying new rear air shocks. |
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...I purchased new passenger side glass, and protective taped it for installation, then... |
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... installed new chrome around instrument cluster. |
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Passenger door is out of alignment, an anchor plate is welded to bottom of door, chain attached... |
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...a hydraulic puller goes to work ... |
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attached to a sturdy chain, pulls door back into
proper shape... |
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...door is corrected, then removed, anchor brace
cut
off, and prepped for primer. |
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3 and often 4 coats of primer paint is applied..
Paint must dry for at least 15 minutes, before another coat is painted. |
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Modern urethane paint comes in two main coats.
The first one is the BASE COAT. It must be applied with a 15 minute drying time, no later than one hour between paint coats. Mark is applying 3 coats and often 4. Each coat is dry, yet still somewhat moist. The actual color of "Light Montana Sky Blue code # 48472" has a dull look" not yet fully recognizable... |
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...the second coat of modern urethane paint is the
CLEAR COAT.
Once the BASE COAT painting is done (there can be 3 or 4 or even 5 of the BASE COAT) then the CLEAR COAT must be painted in the 15 minute to one hour time... ( again there can also be 3 or 4 or even more) The convertible top bonnet cover shown here in total of BASE COAT/ CLEAR COAT has as much as 12 coats all together. (This does not include the gray primer paint which might have an additional 7 to 15 coats) |
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The "urethane" painting procedure of BASECOAT/CLEAR
COAT is an extreme labor intensive job. Once finished it gives a
mirror like appearance. "The enemy" are bugs, some so small one cannot
even see them, they are attracted to chemicals in the urethane...
Exhaust fans are running at full capacity. Doors are not opened, and even lights are turned off completely during the drying times. The best time to paint is when it rains. Most bugs are absent. |
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The next day the convertible is put outside to dry faster in the sun. When a slight rain started to appeared, I mentioned: "The car is being baptized," we then quickly put the car back inside. |
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Convertible top bonnet cover, trunk lid and hood are
painted separate from auto body.
This includes doors, door trims, front splash pan, dash parts, windshield frame and front cowling not shown here. |
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The "showpiece of custom imagineering" is the
convertible top bonnet cover, still in BASE COAT, is attached for a test fit. It will be removed again for final CLEAR COAT paint process. |
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Stainless steel trim surrounding the convertible top
cover, Mark holds in place over dried final clear coat. The BASE (color)
COAT/ CLEAR (clear} COAT urethane, arduous painting process, takes
then
30 days to fully cure. |
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While painting continues I refurbish the headlight housings... |
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and spray paint them with a rust preventive black. |
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I also paint ... |
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...floor of car with rust preventative black paint |
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The trunk separator is custom made out of pinewood
in two panels and 6 custom made holding clips seen here, they will be folded upwards for final installation. |
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Trunk panel is painted white..
Front side panel I varnish. |
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A metal art shop from Boston crafted Kaiser
scripts
out of steel for me. Scripts are larger than twice the normal script. |
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Bill, father of David, volunteers by painting this custom designed metal Kaiser script for me. |
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Bill checks to see if the colors match. |
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It fits perfectly on this area of the front facing pinewood. |
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After 30 days the paint is cured, the car then
gets
buffed to clear ever so slight paint imperfections. In the top -up position we test the flow of the future vinyl top with an old blanket. |
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The yellow tape shows approximate future area of the large plastic-zip-out rear window. |
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In the down position, the top's frame is tested
with a neon tube for clearance. |
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New wiring with exact instructions is purchased
from a Kaiser Club member wire specialist. |
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A unique tool measures the exact wheel bolt
placement of 4 1/2 inches for future steel rim or spoke-wheel purchase. |
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... dash metal gets refurbished... |
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...and primed... |
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including rear floor and new "imagineered"
back seat steel braces. |
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Smaller items are meticulously primed with many coats
also... hood latch - steering column cover - inside door metal, customized from a 52 Buick. |
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and then, like this glove box door, gets painted:
3 base coats and three clear coats... sometimes more. |
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Driver's door now gets needed attention parts of
bottom were paper thin... after new metal is welded in and dented areas are pulled straight... |
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Mark again applies the "lost lead procedure"... |
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...then smoothened with file and scotch brite wheel. |
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Now ready for the 6 to 8 primer applications, with
lots of sanding in-between. |
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New script " Custom Designer Classic by EG"
is now installed below the Kaiser name ... |
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...on the pinewood panel between trunk and front.
all other scripts were removed from the convertible. |
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Now that the paint is dry, car gets a good washing. |
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Carlson Auto tested various "bonnet" fasteners.
Seatbelt lock and receivers proved to be the strongest... |
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...once "bonnet" is locked in the down position. |
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Bill, Mel, Matthew and Mark are now installing
the heavy door. |
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Mel and Mark are now carefully lifting the already painted fender into place. |
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...while protective tape is applied not to damage the painted parts. |
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Beltline stainless steel now gets adjusted. |
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A new slot is now... |
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"wheel-cut" into top of inside door metal. |
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Stainless trim gets adjusted to fit the newly made slot... |
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...for proper fit... |
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...since I am using the inside door metal of a 1952 Buick >with window and vent glass and their manual crank mechanisms/lifters< that will fit the 1952 Cadillac convertible windshield and frame. |
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Door mirror is installed... |
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...for proper positioning, |
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including the new driver's seat. |
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A new copper fuel line is installed; unfortunately a recent, previous installer had used "brake line metal tubing" for fuel supply lines,this could cause rust and cause damage to mechanical gas pump. |
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A new 6 volt booster pump will also be installed
shortly after the fuel tank, with a new on/off switch on the dashboard. |
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I help install new antenna wiring which Mark prepared for me, using coaxial TV type wire... |
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...onto an aluminum bracket, I designed myself, to fit onto the refurbished bumper bracket... |
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...which will be hidden from view behind the massive
Kaiser's driver's side bumper guard. |
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The six unit bumper (not counting the many bolts,
etc.)
is now assembled by David and Mel... |
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...and then installed, under Mark's supervision. |
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...Mark also gives "booster" or auxiliary fuel
pump
a final check... all A-OK ! No leaks... works great. This 6 volt pump was bought at the last "Daytona Beach Spring Swap Meet." It was tested thoroughly...especially when "shut off " ... that the "Kaiser mechanical fuel pump" can pull gasoline through. |
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A 2 barrel air filter was purchased at a local auto
salvage yard... |
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received a fresh coat of primer... |
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and "imagineered" ... |
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...for the Kaiser's 226 engine... |
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...then, with a new 6 volt battery the engine
was
finally started... |
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...it's alive!" a 'milestone' is reached...
photo shows whirring fan blade and new 6 volt battery. |
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I removed the heater motor unit from passenger side cowling, then... |
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...the heater motor ... |
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armature core... |
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is reworked... |
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copper core is filed... |
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new wiring is carefully installed... |
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and housing, the 'squirrel cage' are primed and then
painted black.
This is reassembled, and the passenger side front fender can now be re-attached. |
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Passenger door is prepped for primer... |
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and then tested for proper alignment...
...also new mirror installed. |
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New battery and fastener clamp is installed. |
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New fuel filter... |
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...lines for rear air shocks... |
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New 'bump' stop plate... |
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is made, as well as... |
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...a new bump stop support, 5 inches long, is welded
directly to the frame. This is needed, since the rear wheel wells
were shortened for the down position of
the convertible top. |
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and transmission floor-shift chrome knob are installed |
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New wheel well structure is welded... |
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...and cut. |
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New metal... |
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is hammered into place... |
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and then welded. |
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new wheel well as seen from the bottom, |
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and from the top. |
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Now that the rear wheel wells are finished,
attention is again focused on the doors. Primer is applied, ready for paint, however... |
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...Carlson Auto is re-welding the door metal
around the vent window... |
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...here is the work for the driver's door, and...
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...here is the work for the driver's door, and...
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...work for the passenger door.
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...work for the passenger door. |
Use the links below to continue viewing the various stages of the reconstruction
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Total hits on all the car pages