Last month, we followed along as Terry Hegman cut and created the handful of aluminum pieces that would eventually come together as one to form a top for Phil Whetstone's '32 Ford roadster. Each panel was formed to fit against the buck Terry made, and the overall look of the top was starting to come together. This month, Terry's going to put all the finishing touches on the top, beginning with the fabrication of the rear-window opening and culminating in the welding-up of all the pieces to make one solid top.
Care must be taken when welding long seams such as those found between each top panel. Since the panels were carefully crafted to precisely fit the buck and each adjacent panel, it would be a shame to lose that meticulous fitment due to overzealous welding and hammer and dolly techniques. When Terry began welding the panels together, they were first tacked together in staggered increments until it was certain the panels were secure enough to be finish-welded and nothing was going to wander. After the panels were tacked together, they were finish-welded in 2-inch bead lengths to reduce the amount of warpage and stress applied to that particular area. A light dinging spoon, along with a body dolly, was used to relieve the localized stress caused by the rapid heating and cooling during the welding process. Once the entire seam was welded solid, a combination of body files was used to knock the weld flat and work the entire panel smooth. With the welds ground smooth and the offending low and high spots hammered out, a few more things, such as window moldings and attachment points, were sorted out before the top was ready to be sent off to the painters.
Here's the Steve Stanford drawing from which Terry works. | 
Here's where we left off last month. The four main panels have been fabricated and are mocked in place on the buck. | 
The first step is to form the pieces that will make up the rear-window moldings and surround. A wooden buck is fabricated that perfectly replicates the shape of the rear window. |
On the opposite side of the rear-window buck, the metal is formed to create a rolled edge, similar to the shape of the rear window of a Deuce coupe. | 
Once it is welded together, the window opening is welded to the rear curtain. | 
The window opening is welded together, ground smooth, and looking good. The Deuce look is definitely becoming evident. |
The four panels can be welded together now that the last bit of fabrication to the side, rear, and top pieces is finished. | 
To minimize warping, each weld is kept less than 2 inches and done in an alternating manner, front then back, etc. |  |
Once the entire seam is carefully welded, it is filed smooth using a number of flexible and flat body files. |  | 
After each short pass, Terry uses a dinging spoon and a dolly to relieve the localized stress along the seam caused by the heating and cooling of the welding process. |
The next step is to trim the edge of the top where it meets the windshield and weld the top and side skins to the header bow. | 
The next step is to trim the edge of the top where it meets the windshield and weld the top and side skins to the header bow. | 
Peering inside, it's possible to see the few seams that resulted when the panels were welded together. |
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The profile of the aluminum top fits the DuVall-style windshield perfectly and still provides ample head room inside. | 
A pair of garnish moldings was crafted out of aluminum to cover the seam of the headliner over each side-window opening, as well as one for the rear-window opening. |
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