Archive for body

Ferrari Daytona Deer Accident

This Daytona came in recently for repairs after it struck a deer. We had to rebuild so much of the front, all the tubing was bent and radiator was damaged. We were happy with how it came out. It was a struggle to find out how the front plexi-glass should look when finished because there were so many different details from the cars we photographed.

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Repair to the front of a Ferrari Daytona

Ferrari 365GTB/4 Front repair

Accident Repair Ferrar 365

Front end to a Ferrari 365GTB/4 Daytona

Bodywork repair on Ferrari Daytona

Ferrari Daytona Bodywork

 

Ferrari Daytona Coupe Early Production

Plexiglass front Daytona Coupe

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Alfa Romeo Zagato 2600

We are very close to finishing up the body work on the Alfa Romeo 2600 Zagato after some hassles on getting information on this rare car. This car was very rusty as though it came out of the Long Island Sound but now the body is all steel again and its going to be sealed and painted to make it last forever. The car was built with layers and layers of steel sandwiched together in certain areas which caused massive puffy rusted sections on the bottom of the doors and rocker panels.

We also had to remedy some accident damage and make a bunch of missing trim and even the front turn signal marker lights. Thankfully I found lenses but couldn’t find the bulb holder assemblies so we had to make these as well as bumpers, a full trunk lid and other parts.

Alfa 2600 SSZ

Zagato Alfa Romeo Restoration

1966 Alfa Romeo 2600 Zagato

Alfa Romeo 2600 Zagato 1966

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Rust in the Rocker Panels

Our customer wanted us to re-paint this 330 GTC because the paint was faded and cracking but the car appeared to be very straight and showed no signs of rust or accident damage. As we exposed the bare steel under layers of blue and red paint we found some minor accident damage at the left front headlight that was expertly fixed years ago. The other damage was from the infamous “rust worm” slithering about the rocker panels and rear wheel arches. There wasn’t any bubbling in the paint because someone (expertly) applied stainless steel tape over some perforations in the bodywork which did a great job sealing water from behind and lift the finish.

I cut away the rocker panels and cut the inner structure from behind the rear fender arches so I can properly fix and seal the panels so they’ll last at least another 45 years. Water can get into the rocker panel area but there are many areas for it to leak out but there were these big sand bricks trapped inside which allowed the water to linger in there for a long time which caused the most damage. As bad as it looks, there won’t be any major re-construction other than a few new inner sill struts and new rocker panels.

Refinishing a Ferrari 330 GTC

Refinishing a Ferrari 330 GTC

Rocker panel Ferrari

Rocker panel Ferrari

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Hundreds of Hours of Labor

Carrozzeria Touring Berlinetta

Carrozzeria Touring Berlinetta

Ferrari Headlight detail

Ferrari Headlight detail

Touring Carrozzeria Body Dashboard

Touring Carrozzeria Body Dashboard

High Build Primer Ferrari

High Build Primer Ferrari

Here are a series of photos of the block sanding process on the Ferrari 166 Touring Berlinetta. The sheet metal is all sorted and gaps are perfect but the body needs hundreds of hours of serious elbow grease (sanding) to make sure it is all straight as an arrow. Syl isn’t scared of the “mud”, he completely fills in all of the door and hood gaps allowing him to block sand right across them so when the light hits the highly polished top coat you won’t see any waves or change in reflection.

Even though the grill we made fit the opening in bare aluminum, Syl spends hours making it perfect with skim coats of body filler and attacks the headlight rim contact areas with the same level of perfection. There isn’t any room for error when working with super fine trim that is used all over this car like the delicate headlight rings and the low profile windshield and rear glass surrounds. Imagine these surrounds,  start with a long  section of 1/4″ aluminum rod and whittle it down so only a quarter of it is used.  We re-made this trim because the delicate original material was destroyed when the car was disassembled.

Right now, the car is sealed up in high build primer with a blue tinted epoxy primer that seals the polyester filler from moisture and greasy finger prints. Now we have some more fitting here and there before it goes back to Syl’s shop to work out some more details such as the incredibly complex belt-line crown that goes from the headlight to the tail light..

We’ll probably have more hours in sanding and painting the dashboard that it would take to paint an entire late model car like a Mercedes or Honda. The dash on this car is a thing of beauty but it requires a perfectionist sicko to finish it because like the rest of the car, the trim that surrounds the gauges and switches are like string bikinis

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An Amazing Way to Build a Trunk Lid

This is so cool, it must be some sort of World War II Aircraft Manufacturing technique for welding aluminum by smashing it together that was used for cars. This trunk lid was made by Carrozzeria Touring in the late 1940′s and as much as I curse the way they build cars, this is some of the most amazing craftsmanship I have seen. Since it isn’t adding any new material its keeps the panel very light and super strong and without the heat of welding, the panel doesn’t warp and distort. I’m guessing that the force of smashing the two aluminum pieces together in a focused area causes enough heat to melt and stick them tight.

Welding aluminum with a punch

Welding aluminum with a punch

Aluminum welding technique

Aluminum welding technique

I’d like to see other examples of this attachment procedure and find out what it’s called.

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A 330 GTC in Preparation for a Paint Job

Re-finish Ferrari 330

Re-finish Ferrari 330

It doesn’t look bad in this photo but the paint on this 330 GTC is displaying it’s age with small cracking, a few minor rust bubbles and areas where its flaking right off the sheet metal! I was looking carefully for signs of the original color which appears to have been blue from new. There is a hint of red paint around the front window but I can’t tell if the car was red at one time or if it was just some extra protective coating in an area that needs lots of rust protection. The car will likely be re-painted a dark blue.

330 GTC in for Paint

330 GTC in for Paint

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Ferrari 308 Door Repair

It’s hard to tell how deep the crease is in the photos but the door skin actually split at the rear edge and crushed the framework at the closure area. The crease went on the panel behind the door as well so Nate took the door apart and pulled the fuel tank to access the inside of the rear panel. I had to make a few custom tools to get inside the door to shrink the sharp crease and other dents without having to remove the entire skin. It would have been a bear to remove and replace the skin because the door fits so well from the factory and to duplicate that is tons of work. A complete replacement door would have been equally intensive so my gut reaction is to fix what you’ve got

The paint match is excellent, the car is the newer tint of blue sera metallic, a slightly lighter shade than I have seen on older cars like Dino’s and 330′s. I like the older shade more because the paint contains more gray where the shade on this car has more         violet in the tint. Either way, I am happy with the results, the car is fully polished and looks killer

GTSI Door repair

GTSI Door repair

Quattrovalvole 308 GTS

Quattrovalvole 308 GTS

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Aluminum panels, rough and smooth

The panels on this Aston DB-4 GT Zagato probably looked like the firewall on this Auburn Special Racer before being smoothed and polished to perfection. Can you imagine the time involved in filing and sanding all the welds let alone building such a complex body. Hello? Isn’t that what body filler and paint are for!

The Auburn firewall is super cool, made by someone who had the talent to smooth it out just like the Aston but chose to leave it rough for effect. These cars were photographed at a VSCCA event at Lime Rock Park last Friday.

Zagato Aston Martin DB-4

Zagato Aston Martin DB-4

Firewall on Auburn Special

Firewall on Auburn SpecialAuburn

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Testarossa Hood

A customer swung by with the pictured Testarossa hood asking if we could repair it. We said we’d check it out, and he asked for a very rough ballpark estimate of what it could run – you know, is it $20 dollars or twenty-thousand? Initially we said it’d be a few grand, but when Eben saw it, his experience as the panel beater and sculptor rang true, with an estimate of about $5k to make it perfect again. The aluminum can only be worked so much, and new material would have to be welded in.

It was a better deal to just replace it with a used panel and let the owner keep the crushed one as a souvenir – you may ask, how’d he do it? The guy he bought it from did.

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100mm Carello Tail lights

These are 80mm Carello Tail lights, where can I get the identical ones but 100mm in diameter? These were on a Vignale Ferrari 225 Berlinetta at Cavallino and I need the 100mm ones for the 166 Berlinetta that we are restoring.

Tail light

Tail light

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