It doesn't seem possible, but here we are kicking off the 10th anniversary of SRM's Road Tour program. When this all began, the idea was to prove that a contemporary street rod, constructed with parts from our advertisers, could be a fun, safe, and reliable car that could be driven coast to coast, border to border. To prove that point, each year we've built a car, stuck our very own road warrior, Jerry Dixey, behind the wheel and send him off to visit NSRA events all over the map.
As always, the Road Tour rods are a collaborative effort. This year the car is based on a J.B. Donaldson '36 Ford three-window body and a Total Cost Involved Chassis with Air Ride Technologies suspension components. Power from a Roush-built small-block will be delivered by a TCI Automotive AOD. Assembly will be handled by Hot Rods by Dean, and the Thom Taylor-inspired form carries PPG's colors.
Donaldson, a well-known manufacturer of industrial fiberglass products and custom steering wheels, has been tooling up to build '35-36 three-window bodies for some time; after investing three years and $150,000, the bodies have become a reality. An exact reproduction, all the components are interchangeable with original parts. (Donaldson also produces '35-36 roadsters and the American Peerless cabriolet for '32 Ford frames. Check out the Web site for more info).As J.B. tells the story, these new bodies are built in a mold made from the "cherriest original '36 three-window body we could find." After coming up with a near-perfect example, it was turned over the SO-CAL Speed Shop in Pomona, California, and Bill "Birdman" Stewart. He not only removed the near from perfect, but also 2 1/2 inches from the roof. The result was spectacular, with a perfect profile from which to make molds.
Made in five sections, the body mold is bolted together and then mounted on a rotisserie. Fiberglass is entirely hand laid, and then it's off to the 180-degree post-curing oven. The end result is a strong, one-piece body of uniform thickness that resists warping--and doesn't smell like fiberglass when it's done!
As we all know, one of the major expenses in building a street rod is paint, and this is an area that makes Donaldson's bodies a bargain: They're available in paintable black gelcoat, or they will custom mix non-metallic gelcoat colors of your choice and you can skip the top coat. Of course, even if you do decide to apply paint, think of the advantages to having gelcoat of the same color--think of it as automatic chip repair.
Along with their superior finish, Donaldson's bodies feature stainless- and mild-steel inner structures; the firewall, dash, decklid, garnish moldings, rear fenders are included; and the doors are hung and all glass is cut to size. There is also a long list of optional components and items that are available separately.
Our intrepid photographer, Jason Walker, has been following along as J.B.'s crew built our Road Tour body. It's already been mounted to the chassis, and soon it will be off to Hot Rods by Dean for final assembly. Of course, we'll be bringing you bolt-by-bolt coverage as it all comes together, and then we'll bring you mile-by-mile reports as Jerry Dixey drives it around the country. You'll be able see the car for yourself at many of the NSRA events around the country, and if you make it to the Nationals in Louisville, Kentucky, we've got a special treat lined up because most, if not all, the Road Tour cars will be an attendance.
One of Ford's most elegant...
One of Ford's most elegant pre-war designs was the '36 three-window. Thanks to a little artistic tweaking by Thom Taylor it looks even better.
This is the mold for J.B....
This is the mold for J.B. Donaldson's fiberglass '36 Ford body; it's on the way to the curing oven.
When the one-piece body comes...
When the one-piece body comes out of the oven, the quality of the gelcoat surface has to be seen to be believed. Some minor work on the seams and it's ready for paint or to run as is.
This is one body that doesn't...
This is one body that doesn't lack for inner structure. Here, the stainless-steel cowl reinforcement is being cut out on a water jet.
As we said, no lack of reinforcement....
As we said, no lack of reinforcement. Stacked on the table are plates for the cowl, kick panel, doorposts, and latch posts that will be 'glassed in place.
Now, to drive the reinforcement...
Now, to drive the reinforcement point home, this is the steel brace that runs along the doorsill and ties the hinge and latch posts together.
To stiffen the area where...
To stiffen the area where the seats mount, large plywood panels are 'glassed into the floor.
For safety and security, bear-claw...
For safety and security, bear-claw door latches are used. Stock external handles or solenoids can be used with them.
Donaldson uses a unique approach...
Donaldson uses a unique approach to building the doors. A framework that holds the power window assembly and the glass channel is put into place before the inner panel is attached.
After the doors are "built,"...
After the doors are "built," the inner panels are bonded on. Access holes are provided to service the innards.
For strength and to make sure...
For strength and to make sure the doors never sag, the hinges are bolted through the fiberglass and steel reinforcement plates bonded into the doors and the body.
Like the body, the fenders...
Like the body, the fenders are hand laid. This is the filler panel between the front fender and grille.
Just like Henry did it, the...
Just like Henry did it, the front fenders and filler panels are bolted together.
Aligning the frontend components...
Aligning the frontend components of a '36 could make a preacher swear. Donaldson has developed these adjustable supports to simplify the task.