The Cal-look Lounge

My friend tony's ghia. First thing is to fix damage from getting hit and the rust from the battery acid leaking into bottom of 1/4 panel after getting hit, Kinda a bummer! Its the only rust on this original paint car that where starting with.

Couple shots of the rust

First I drilled out spot welds and removed tail light bracket

After roughing out taillight hole, Now I can use the tools I made to pull and get length back in 1/4 panel. The white peice is a hunk of nylon I growned into the shape of the bottom of 1/4.

After getting it into rough shape, I taped a taillight into place to check shape.

That's awesome Danny! Would you be interested in pulling a dent from the rear fender of my GTV? It's a good fist sized dent, been there for decades. I'd really like to have it pulled without harming the original paint (as little as possible at least). I can't find anyone around here that I trust.

Couple shots of loren's 58 convertable ghia, Poor things been hit and then a nasty clip job and then rehit and then somebody brazed and  tryied to learn how to mig weld new driver's front fender and nose skin back on. Well after helping loren to cut all the bad stuff back off, Now its time to resurrect this thing back into a car again!! First thing is to reclip and get going on the bad repairs on sheetmetal.

Now onto the front fender, After cutting all the nice work off and starting over!!

Now time to start filling up some of this mess!!

Couple more shots and pictures !!

Just a patch at a time! The tape is where I'm going to return that edge.

Now for a couple final shots, O-YA and finish that fender!! I will straighten the fender about 90% and then do all final tuneing after rewelded back on car to get the final shape.

 ::)

Hey Danny, show them the bitchen vise grips you made to do my pan halves last month, the tools you make are as cool as the finish work you do, can I borrow that nylon dolly when you're done? they started pulling the dents out of Beccas ghia today and I'm gonna need that to get that straight. 

Thanks randy, Will send tool in mail friday.

Nice work Danny  ;)
As you are speaking about metal surgery. I have a hole in a bay window roof. About 10" by 10" that was made to put a ventilation hatch.
What will be the best solution for a newby to fill it?
I fear to butt weld it and wrap the roof  :P

Thanks  ;)

Hi J-F, If you can touch both sides you can butt weld it! First make a patch with some shape into it to match curve in stock roof shape. Then clamp and scribe, then cut and file to scribe mark. Big gaps are a no-no. then weld and carefully grind just the weld to same thickness as metal. Now hammer welds and bump low spot up and repeat til the roof holds the shape. warpage is caused by the welds shrinking and to fix that you need to stretch the welds. I hope that helps. And practice your welding before you start with roof. Get your machine dialed in !!!!

Thanks for the advice Danny.

I handle quite well welding. But I often have problems to control warpage. :-\
I try to leave a 1mm gap between each parts and I cool my weld with air pressure.

But well, practice is the best way to learn  ;)

No gaps, They tend to pull or shrink and warp. Just let cool down slow, And are you tig or mig welding ? I never use welding rod thicker than aparent metal when I tig. I get .023 steel rod when butt welding 20-18 guage. And dont start hammering till metal is ground to proper thickness after welding. I use a die grinder with a cut off wheel and just shave welds down. and lots of tack to hold patch, About 1/4 to 3/8 apart when finished tacking. And dont hammer tack welds just between them. The reason is that when you hammer the tacks they grow and you get big gaps. Take your time and fit and file patch to fit. No light between parts tacking !!!!

 dam danny , easy on the guy... maybe time for a trip to the fridge ? or ?...see you tomorrow, rear cage is off baja for powder coat trip..little prep needed around a few someone elses welds.. bill

I mig weld.
Thanks for all those directives. I will try it this way  ;)

Thanks for the tips Danny - I will PM you later today  ;)

u are a master ;D

Thanks Mr. 58.

Building new sheetmetal for engine bay and makeing rearbody panel removable on tonys ghia.

Started with two very nice cars to make my patterns.

These are the prototypes and now I can tune  on the tooling to make perfect and start makeing them. They will also be a 1/4 inch wider from left to right to help out with any tight fits with stroker motors. These will be for sale in about a week.

Looks great Danny! I like those seams...looks factory!

Nice stuff!  8)

Thanks nico! Tony, we will cut the stock channel that hold engine seal and rosette weld from the backside of new sheetmetal. I hope that make's since. Will show progess pictures  of install in a few days. 

Well it started as a NOS apron, and now , Not so much!! Got started filling exaust outlets, New bottom and one side tacked in

Patch tacked in and then welded

All welded and hammered flat and then filed flat, No bondo baby !!

Good Works Danny ;)

Magne

Awsome work Danny..!!......Whats your process for ginding and sanding the metal...?

Thanks guys, Mags thats what I am fitting your panel to. After welding I take a cut off wheel on a die grinder and shave down just the weld and not grind the sheetmetal on both sides till the weld is the same thickness as metal. Then I go over it with a 90 degree grinder with a brand new 36 grit disk and then I start hammering on the panel to get the shape needed. I run a vixon file over the panel to check for my high's and low's and see where I am at with shape. And I if a little proud, I run a friction disk over it to shrink down any high spots. Hope that helps.

Damn Danny, you've got patience.

You comin down for the Classic?

Thanks zack, Its the weed!! LOL. up in the air about comeing down south.

Great work!  You know, I never knew that it was possible to patch, fill and weld thin sheet metal panels and work them to the point where they don't even need filler. Thanks for showing and explaining how you do this.
Jeff

You always learn something from seeing Danny work, this time what I learned most from is the edge he welded on the inside before he closed the peashooters.
Great stuff Danny!

Thank you guys.

Couple shots of the heat sheild

Couple more, Mags will get shipped in the morning.

man, I have skill envy!  Just love the stuff you do!

Thank you martin.

Who doesnt? :)
Danny you re the man :)
P.S. Do you Guys have Amnesia there?
It does what the name says :)

Started trimming all the edges and flanges

Finished trimming all the original engine bay sheetmetal. Then wirebrushed and chemically cleaned for any surface rust, Did it a few times and now wallnut shell blaster can just slightly go over and clean.

I carefully cut the original engine seal channel off and it will be reused and spotwelded on the edge of new sheetmetal

Will be useing this type of spot welder to weld most of the new engine bay sheetmetal, So it will have a factory look when all back together.

Started mocking up new metal. And this is the first time ever in car and hardly any tuneing to get to fit.

Couple close up shots of the detail of the fit. They lay in very relaxed

Couple shots with a german vw breast plate clamped onto edge, Also enginebay is a 1/4 inch wider on the sides for any stroker motor tin issues that  may acure down the road. And calling it a day and going to have a beer!

OK two more then a beer!!

Looks sweet!

ok danny, show a picture of satan, I mean BELLA, your new helper, why you are loosing patience, sleep, and not getting more done, DUE TO...constant baby sitting. bill

Thanks Danny ,
got the parts last day
Mags

Again glad everything showed up mags ! Thanks JHU, And Here is Bella the devil dog, My 3 month old husky.

Well got started cutting rust sections out and got going on with the metal prep or chemical to get rid of rust before blaster.

Some of the crap I cut off.

Made real nice cardboard patterns from another project at my shop that is pretty much virgin. Now transfered to alum and cut out.

I made tops a little long and then used my tank roll dies on bead roller to turn edge . Now edge blends real nice into 1/4 panel.

Playing around with some lay-outs for placeing some beads, Trying to copy the beads on firewall.

Die's I have , Without turning some new ones.

A set of visegrips I had to rework for this project.

After being rear ended in a collision and cutting all sheetmetal and supports out the rear of the car is sagging. So I am makeing a brace from bumper bracket mounts and now I have someway of jacking the rear of car back to the proper place while I am welding car back together. And hopefully it will stay !!

Forgot a shot of some of the cut out rust

PM sent.

you are good man

Thanks fredy, But sometimes I ask myself why.

Hey Danny, sorry I didn't post pics of the ones you made for beccas car, but they had already put the KGP&R ones in. So these will go in my vert. When did you get the new puppy? How is Yoda taking it?  Next time you come down bring Bella over so Clyde has someone to play with

Got Bella when down for the classic. She is a hand full, Dam she pee's every 10 minutes it seams! That and she likes to run and body slam yoda, Yoda try's to catch her but being 15 she is not as quick as she us to be. Cool that you did not put them in, I am makeing the inner braces and would like to put a set on your panels. They will be made from heavy'r guage for strength.

Had to make or reproduce the inner brace's for battery trays.

Close up of bottom, Originally they where made from 20 guage and choose to go with 18 guage for a little more strength. And the steps from pattern to parts being made.

Finnally got around to rolling some beads.

Some finished parts and time to start welding this thing back together.

For those that have never rolled a bead on bead roller. When finished, the ends are not finished and here is a tool I made to hammer down and shape or finish end of bead.

This is a great thread. Thanks for sharing all this stuff.

My pleasure, Glad you liked them!

Danny, your work is exceptional!!!
when we think we've seen it all, you step it up another notch...
geeses, you can build a whole car if you want :)
Thank you very much!

Getting started on some rust repair. First thing is to make some patterns and I was lucky to have a donner corner of a 1/4 panel to kinda work from and I have a nice unhit corner for final fit.

Getting started roughing peice into shape and checking to see if it lays ontop of panel relaxed, Still a ways to go!

After some hammering and a litlle planishing with my german wheel its getting real close.

Clamped onto a virgin 1/4 , I think I will leave it alone tll  I get the edges or inner structure remade on the bottom of rusted car.  So I can see if there is some fine tuneing on shape.

Besides a hard rubber pad and some hammers, These are the tools I used. One is a hand held wheel that I restored, Had to make the block that holds upper wheel manually on the mill and my other wheel that was wood grained by artist john rayburn. Thats bella next to it, Not john ! LOL !!

Also my Eckold  power shrinker/stretcher made in switzerland, Great machine. Look up eckold and check out the trick machines they make for manufactureing in the automotive industry, I used a larger version of this machine to make frame rails for a car when working at a studio building concept cars.

Couple shots of engine bay.

Superb! Great work (as usual!)  ;)

gr
Wout

Thanks peter, There is a forum called (metal meet .com) Check it out! There is some REALLY talented guys on there, and some mind blowing projects. Again thanks. Wout thanks again also.

that is some fine work you got there :-o
you really know what you're doing!
glauco

This thread is awesome.  8)

Thank you nico, Glad you enjoy them ! Well a little more progress. A reminder of what it suppose to look like and whats left of the right side bottom.

Now for one of the last peices I need to make.

Well , All but one little peice to go, And then its time to glue this thing back together !

Here is a four tab hood I got to repair.

Couple more shots of repairs needed.

Tacking and welding patch into place

These are for you JHU, Started by grinding just the weld with cut-off wheel and then came back over with a new 3.0 inch 36 grit disk and knocked down the rest of weld.

After grinding I hammer and dollied shape back into area and started filling and metalfinishing

After welding and metalfinishing I layed out and drilled holes for handle. And here is a male/female die I made for the embossed area on lower part of handle.

And the finished hood handle area.

Thanks Danny, you make it look easy ;)
Great work as usual!!!  But how are you going to fix the "waves" you mention on the hood... Would be cool to see that too... If you have the time?  :)

Great thread Danny! thanks for the step by step pics and explanations.

My pleasure, Glade you like ! and JHU Thats going to be hard, Its kinda a bump and feel thing if you know what I mean ? First thing is make sure ALL ! body lines are where there suppose to be, Then run a file over area and figure out what happen or what caused any of the low spots. After 30 something years _ucking around with these things, I still have to be in the right mood to fix the embossed areas on a vw hood. Not a thing to do if ya had to much coffee and in a hurry!!!!

I love this thread - I am learning ALOT about this "_uckin' around with metal stuff" at my new job  ;)

http://www.norwegianhammerworks.no/

Really inspiring thread! Makes me wanna start on my friends '56 barnfind Ghia!

Just want to say a big thanks to texas tom for helping me with the math to raise compression on 40 hp motor. I didnt have a fly cutter so I widdled one out. Now I can raise compression. I am at almost 5000 ft here in northern nevada. also checking to make sure both side are at same height, I dont do this stuff that often and I get parinold machineing stuff like this

Now after finding center, I started machineing chambers to get compression ratio I needed. Tom was so on the money, He gave me three sets of numbers from a picture and measurement of chambers to cut to. I started with .052 to get CC's I needed and was on the money!! Then went to finish set of numbers and machined and again on the money for amount of CC's. Ole Texas Tom really shines when It comes to machineing and engine building!!! Again thanks my friend!!

Now that I've got motor finished I can start on the manifolds for the dual pci-1 carbs going on, With any luck I will get both carbs useing stock choke cable. First I cut stock flanges off stock manifold. Then I made plate so I could spin in lathe and bore center to 1.0 inch

Now a 1.0 dia tube fits, Now I have to swedge end of tube, to 1.125 carb side of manifold

A slightly rusty early ghia convertable. OK Low light! Hard for me to say that. Anyway after cutting and after walnut shell blasting and chemical cleaning rusted area's

Nice heater channels  HUH ?

NOS panel on left repro peice on right. They where stamped wrong. Wireing loom runs along passinger side rocker. So on right side rocker theres a notched stamped for wireing loom to clear. Left side should not have notch like stamped repo part. So I hammered out notch to look like stock nos peice

Now starting to reconstruct and weld in rust patch peices I made.

34 chevy street rod I am doing some restyleing on. These are before and after shots and what it took to get there.

If you look at last picture, You can see where stock frame rail sticks out past fender edge. And more nasty patch work from fixing cracks. Both fenders were like that.

Its hard to see because of fenders are blasted, But right side fender is beat up, But very saveable. Second shot is after some hammering.

After bobing off and refinishing bumper end. Started to fill area on fender were bumper came underneath

Now that patch is welded on and edge returned. I can start to focus on filling cut off area's on left side. Time to make a flexable pattern, a cool little trick I learned back some time ago. First I coat right fender or the fender to make patch from with a very low tack spray adhesive. Its about the same as peeling a sticker off the paper.

The reason for the contact cement, I lay a layer of 3/4 inch masking tape down , sticky side up and then go back over with another layer sticky side down. So now that there two layers sticky to sticky I can peel off and turn it inside out and have pattern for other side

Now I got pattern for patch panel, Did I mention that metal is .058 thick. Now time for some metal melesting. Peice is roughed out and clamped on to test fit.

Peice now is getting close to start tack welding and another patch added on.

Now welded and another patch made and welded also.

About 90% done. Some details that need to be added

Full pattern I used to figure out where bead needed to be. Tranfering from one fender to other side.

Seriously nice work dude - By the way are you TIG'ing in those patchs  ???

Also did you get that price for shipping my stuff to norway  ??? :)

Amazing work as usual!!!!

gr
Wout

Stuff I have been working on lately at my shop. Manifolds I made for the big 40 HP motor ! LOL

Carb linkage peices I made

Rear breast plate that got reworked a little

Fuel line on the back of fan shroud I fab'd up and breast plate and how it now fits car. 40 hp motor in a 60 sedan that originally had 36 hp. The rear tin is way different.

34 chevy hot rod project been hammer'n on

Rebuilding body around bottom of decklid

Nasty repairs by somebody in the last 70+ years

Repairs on both fender bottoms that I had to do

Pictures of what it looked like when It got to the shop, And the original shape

Few shots of the upgrades at GAB-FAB

Few more shots, About 10 feet of weld

Few more shots.

Love that second shot!
Dang, now THAT is SUPER CLEAN, Danny!
The body lines are SO SLICK now.
REALLY PRIMO work, as usual!
TxT

Awesome work, and thanks for sharing!

Thanks chris!! Glad somebody likes them.

Great work. It's nice to see someone who knows how to use an English Wheel. A dying art form, indeed  :'(

Amazing work! In bare metal you can really see how everything flows together. Fantastic!

Thanks, That means alot to me!! Still have your Ranalah ?

  Thanks jeff, It turned out to be a fun project! Customer really is please'd !! Now onto the next one.

How not to lilke that kind of work?

Superb!!!! as allways  :o

gr
Wout

Again thanks guys !! Glad ya like'm

OMG!!! Super!Respect!
Greets cedric

Well thank you Cedric, Glad you like'd them!!

Danny your work is always top notch! Wish you were still down here in so-cal.

You're welcome good work has  to be appreciated
Greets cedric

Thanks shag, Sometime I wonder why I moved, Like in the winter here!! COLD!

Thanks again !!

Few picture of the latch section on the chevy. Before and after

Seat frames going in my COW-LOOK car. Rewelded stock weld joint after I blasted and wire wheel'd frames. Made some stainless trim peices for the back of rear seat. And peices I made/formed to attach plywood.

Patterns I made for carpet in the 60 bug and kick panels I made. And finished carbs for the big 40 HP LOL!!

Some bumper parts I made.

Peice's I used to make them. Cut from different bumper parts I found.

this is artwork.... ;D

Couple shots of project finished

Few things going on with my 1960 bug. Foamed up inside getting ready to install headliner

My second headliner I have ever installed, and first cloth headliner! Dam make sure your hands are clean !! LOL. Got lucky and found a NOS visor

Got carpet all cut out from patterns I made and ready for cloth edge to get sewn on. And added a empi camber compensator I restored

Linkage I made to open and close chokes on both carbs,And finally got all the windows in.

Motor back in.

nice job , danny  as usual , and i like your fuel line and the way she goes to the pump

Thanks Fabs.

I wouldn't have the balls to install that, i'd screw it up :(
Looks awesome Danny!!

(http://cal-look.no/lounge/index.php?action=dlattach;topic=15833.0;attach=64131;image)

(http://cal-look.no/lounge/index.php?action=dlattach;topic=15833.0;attach=64132;image)

Thanks, Its not perfect , But I did learn a bunch ! It was kinda a ginnie pig for doing my white car. The Cow-Look car. Main thing I learned on rear window section, I started from top down, Next time I will start at bottom and stretch corners in first then work up. But again thanks!!

...................!!!!!!!! :D :o :o :( :( :o :o :P

I really like how tight the fabric is around ALL of the window seams and sheet metal that forms around the door openings. NICE....... 8)

Not bad, Daniel.

Thanks Zack, There was a few bad words said while doing it, LOL

Just be happy it wasn't a ragtop, with a full roll cage like the last time I did an early headliner!

Might be a little ez'r it seems with cage? Could hang side peice's on cage will pulling the thing tight? Kinda like a spare pair of hands !! LOL. Headliners are a bitch period!! Could make a guy have a shot of JD !!LOL.  Or two !!

amazing work . . .     as usual  :o :o :o

gr
Wout

Thank you Wout !!

Danny...... I was checking out the bulkhead panel you did for me the other day and I am still AMAZED every time I look at it!!!! ¨

I just I hope I can be that good one day  ;)

While I'm here - Any ideas for making the rear decklid work on a "pull cord" like the Hood  ??? I have always wanted a matching pull cord for the decklid on the passenger side, One it would be a sensible idea and Two it would look cool in the interior - Any Thoughts  ??? :)

How about 68 and later bug front hood receiver mounted from behind on apron , So its kinda flush? Would have to make sure plunger part of latch swings into at a 90 degree angle from pivot of hinge. Or go to your local  wreaking yard and walk around till you find something cool ? Smaller the better to hide .

Kinda stoked, Been trying to get around to doing this for a year or so. Made a halo type deal for my spot welder. This is a 220 water cooled and heavy enough to do 16 guage. So doing floor pan halves should be no problem! Fun part of restoreing ole cars is trying to make them look like they where done like the factory would have done them! Anyway this deal will let me hang it and turn it, Its VERY heavy !! And can be lifted up and down with a air power'd chain pull.

you do some very very nice work, lovely to see such skilled workmanship.

Well I thank you sir !!

Wow thats nice... Building a mini wolfsburg in Sparks :)

New product I am almost done with. Early ghia front fender bottom sections

WOW seriously cool - do you want a new apprentice Danny????  ;) :)

awesome work :)

One peice at a time !!

Thanks.

Get your butt over here !! I need a helper !!

Beautiful work, blows ya mind  8)

Lookin' good Danny!
I'm keepin' my eye on you . . .  ;)

Well thank you, Glad you like !

  which eye LOL. Thanks

Do you keep a stock of stuff, or make to order?

Hi mike, Most of the stuff I make I have in stock.

I need some patch panels, lower rear fender, rear side below the bumper. 1965 Ghia. Both sides. Do you have something like that?

Sorry Mike, Nothing yet.

Thanks Danny

It'll be a winter time project this coming year. I know there are patch panels available, but they seem to be pretty thin.
I'll check back periodically with you.

expect a phone call VERY soon  ;) :)

Hrmf!

Huh!?  :-\

Danny I know this sounds goofy, but have you ever thought of doing some kind of seminars? Not giving all your secrets away, but just going over some of the baiscs that most of us don't know the first thing about? Like, even rattle-canning, 9 times out of ten, my jobs come out pretty scary. The headliner install, Welding 101.... etc. A natural like you could help a lot of clutzes like me get better.
Do you know Ray Schubert? The two of you guys together, could rule the world.

Enjoyed this thread, thanks for sharing

Hi Jim, Funny you brought the seminar deal up, Been try'n to set a date, been wanting to do a two day deal on Bodywork basics,welding,metalfinishing. Got a few guys that want to come,But waiting for the weather to get better !! Been real cold winter!!. Try'd to get a hold of Ray, Back when you gave me his number. Called and left a few messages, Never heard back from him. Seen a lot of stuff he has done with the vintage speed stuff and its very cool.

I'll remind Ray to call you. Gotta call him tomorrow
 8)

Thanks Jim, Would love to meet him. His build stuff is all over the samba. He make's some cool manifolds for 40-p11 carbs on okrasa heads on 36 HP motors.

Another metal EMPI stlyle scooped deck lid I'm get'n started on. The intake piece's I formed

Just WOW  :o :)

When yer showin' me the nice work on that deck lid . . . I have both eyes open!!!

Dam ! No hide'n anything from ya with both eye's open ! LOL Thanks .

NO! Lol

Danny....Awesome work as always, really like the "eyebrows!  Will you be selling decklids with them welded and "bodyworked" on, or is this a one time project for a customer?  Also, I've always kind of liked the side scoops that used to be made in fiberglass but it would be very cool to have side scoops with an opening / profile that matched the style of eyebrow you have made on the decklid.  The fiberglass ones stuck out too much for my taste and always looked "stuck on" to me. I'm sure if you did them they would look less conspicuous, like they belonged there. I think the fiberglass ones also had a tube that ducted air in to the engine compartment.  I would really be interested in these for my '68!  Really nice stuff!! 8)

Hi and thanks Jeff. I make these from time to time for customer's. Here are a few shots of a 68-9 lid I'm doing. Something I did'nt know that the later lids are almost 3.0 shorter. Made locate'n openings a little more work to look right. I will post the finished decklid when I finish.

Danny, thanks for the reply and the pictures of your work! That decklid looks great even though you're still working on it! If you would ever build another 68-69 decklid with the eyebrows could you PM me with a price for something like that? I'm thinking of updating the look of my car and your decklid would look great!
Thanks again! Jeff

Few more shots . First side's ez, Make'n stuff match is the fun part.

there's alot of skill there! looks really nice!

Awesome work Sir..just been back through this thread with my metal man and got to say it...really nice work..inspiring..keep us updated please Danny...

Looks Great! Thanks for showing your work.

Nice!!!!!  As always very cool stuff....

Just want to say thanks, And appreciate the kind feed back. Here are a few more shots. Getting closer.

And final welding, Eyes are tired !!

DAMN!
Think we can match the blue on my car?
I want one! 8)

TxT

I always love seeing your work Danny....(as we all do).....really fascinating and impressive stuff,

what are your preferred methods of dressing back the welds prior to final bodywork / primer?

cheers mate......Jick

Thanks, Tom/Jick. Few more shots, First thing I do after welding is take die grinder with a cut off wheel and go around and remove weld VERY slow.Just knocking the top off and try'n to get everything to the same thickness.

Now I can start hammer'n and get all my last bit of shape'n. Then run a vixon file over area's and find my shape's that need more attention, Then my final deal is run a block with 36 grit and kind of grain scratch's in even directions. Hope that make's since. Hope ya like the finish.

Awsome as always danny - I finished repairin the passenger floorpan on the 65 today and I used ALOT of your hints & tips  ;

I "let-in" a 400x300 section under the passenger seat (the lowest part) Its all about taking your time  :)

And safety meetings !! LOL Lee.

I love this thread.

Wtf are these "safety meetings" I'm confused (read stoned  ;))

Great info as always!

Thanks dude, I appreciate it.

Jick

Interesting little job I got from mark at wolfsberg west.  His radio hole on dash was a little hacked up and now delete plate doe's not cover hole. So I took two repo delete plates and made one wide one. Originally the plate had seven ribs and now it has nine. Butt welded together and material is .019 thick, Human hair roughly about .003 thick So now hotrodsurplus is probably got his mic out ! LOL. Just kid'n chris.Anyway the final finished part.

Dan,

I am working on a couple of "custom" touches for my 63 Sedan and I am convinced they have come out better since I have been following your thread.  Thanks for the inspiration and little hints and tips.

Glad this stuff can be of use to somebody and thanks !!

Like I told you danny - I learnt ALOT talking & reading your stuff  :)

Lovely work as always  ;D

So they widened a T2 about 1/4 - 1/2" and this was the last piece? ;D

it's subtle touches that win trophies Tom!! ;D

Awesome thread, I wish I had half your talent  :o

Thank you very much ! Glad you like pictures.

You WELDED steel 1/2mm thick?!?!?!?!  :o

I mean this in a nice way man, but you're a freak.  :D

Hell, you should see my buddy lance weld, Now thats a freak !! Thanks !!Helps with a 1.0 or better magnifier lenses in your helmet!!!

LiL something that was brought up by a old friend of mine Mark, For me to paint. Did the metalwork about 8 years ago.

Few more shots

And hopefully the next time I post picture's , It will be painted !

some truly amazing metal working skills you have, and that is going to make one very nice car... Alex

Thanks Alex ! This has been a fun project. Mark (The owner) Has a good eye for detail and made it fun to work for. He is a good mechanic by trade and will be a bitchen car when finished. Kind of cool, even that the car has been on the back burner for 7-8 years, We still throw idea's back and forth to each other on the finishing touch's on car. Will be a well thought out car !!

Hey Danny, that deck lid is like art work!
Just wondering what's goin' on with the hood . . . guide coat or a little surface rust, or . . . . ?

Thanks, Poor thing has been setting for about 7-8 years, Got a bit of surface rust on the whole car. My helper and I have been cleaning with metal prep and I may have the body lightly walnut shell blasted again, to get ready for first prime.

Fix'n a little factory flaw, Unrolled and return'd edge on bottom of fender. Get'n rid of the bump and maken line a little smoother.

Few shots of the finishing metal work. Ran over surface's with vixon file to find and high / low spots and any ding and dents from being in storage for 8 years.

Lovely  ;D

Few more shots of the rear.

Lot's of hameer'n and file'n

Such a straight car, amazing work of art (as allways)!!!
I'm very jealous about your skills Danny  ;D!

Good luck with the paint job.

gr
Wout

Truly amazing quality of metalwork!

How long vixen file do you like to use in car bodyworks and finishing, and what cut types? I would like to try those in my own project and get a hold on the technique.

BR
-Mikko-

Thanks guy's ! As far as file's go, I use the most teeth per inch as you can. Less chance of chatter'n and leave'n deep scratch's. I only really use a file for reading the flat surface. And only when your metal finishing is super close. Here are a few file's I use.

Thank you very much Danny for your advice and input. Much nicer to get going on now.

I really like handcrafting and look up to guys who keep these talents alive.

BR
-Mikko-

The ole girl is getting closer.

i like that car  8)

awesome work as always!!..any more porn for us?

Seems like lately it been ghia season .

Finished peice

One of my customers No light projects.

After a lil hammer'n

Something that follow'd me home. (More Ruf) Swore I'd never do another ghia !! Found this original paint No Light ghia up in reno NV.

Some handy work that somebody helped me with before I got the car

A little progress on 1/4 panel, Guess I saved it huh ? And a NOS section I bought just in case .

Took a pretty good wack in rear corner

Back in shape and bulb holder fit.

Top notch work, as always from GAB FAB!  ;)

Thanks guys for the nice feedback ! Always welcome'd

Some work on tony's Ghia. Had to unfold fender edge , Straighten , And return edge

Pretty big dent and hard to get to, On Tonys ghia

Amazing work as usual...

Yep . . . your work is amazing Danny and you truly inspire me!
Will you please expound on the process of "unrolling" and reforming the fender edge . . . especially what you did on the lower front fenders on Mark's bug?

Thanks guys. The simplest way to describe these repairs Mark. I just unroll the edge by stretching by hand with hammer and dolly til flat. Then mark a new line with 1/4 in tape. Couple ways to do this. I have a pair of vise grip pliers that the teeth are ground / polished smooth,This method works good for tight sharp bends that are curved . On Marks fender bottoms I used a couple different dolly's to return edge. But with that big radi , I drew a few different lines with a marker and followed them as I recreated fender bottom. I hope this helps out or makes a little since. Hard to write a summary on stuff like this, Million things going on while doing it.

Thanks Danny!

Where can one get a set of these files to buy. I need to do my bug as i am not interested in using fillers on my car, i will only used lead free solder.

I would try the Eastwood company.

Any thing new Danny?

Here is a decklid I am just finishing up

Few more shots

Rust repair piece's I made for a low light

Something a little different I did

68 decklid I did for a guy in new york

Danny how much is a late model lid like that ?

ta Ron

http://www.garagefab.com  They did a  Little article on some of the metal work I'm doing in my shop.

http://www.garagefab.com/metal-shapen-fabrication/

https://www.facebook.com/danny.gabbard.7/media_set?set=a.10201232871768311.1073741828.1366839244&type=3  One of my projects I'm building for a customer.

https://www.facebook.com/danny.gabbard.7/media_set?set=a.10212756277846261.1073741867.1366839244&type=3 Another project going on at Gab-Fab

https://www.facebook.com/danny.gabbard.7/media_set?set=a.10202346879257802.1073741834.1366839244&type=3  MORE RUF !!

https://www.facebook.com/danny.gabbard.7/media_set?set=a.4805499939855.186989.1366839244&type=3 General stuff at GAB FAB

https://www.facebook.com/danny.gabbard.7/media_set?set=a.2254896176355.131509.1366839244&type=3  Karman Ghia project I am working on

Hi Danny

I'm sure your update is great but how about a post that us non-Facebook users can see
(like you used to  ;))

Thanks
Darren

x2

https://www.thesamba.com/vw/forum/viewtopic.php?t=548717