It's been said that it usually takes about 10 years to become an overnight success. If that's true, Dennis Lesky, son Matt, and the Ionia Hot Rod Shop are ahead of schedule.
When we first met Dennis in '94 at a big rod run, he was behind the wheel of his chopped '32 sedan, a former B/Gas drag racer with the name Regret painted on both doors. It seems Dennis had discovered patina, of course back then we just called that the characteristic of neat old hot rods.
Dennis had been into things with wheels since racing carts as a kid, and he began honing his considerable construction skills after discovering street rods in the '70s. Fabrication became such a passion that when it came time to leave his day job as a welder at General Motors, starting his own business looked like a great alternative to the boredom of retirement. Besides, if the newly created Ionia Hot Rod Shop needed more help, there was a kind of built-in apprentice program-Dennis's son, Matt, had gathered machining experience along with welding and sheetmetal skills and just as importantly, had developed an eye for what looked right on a hot rod. Matt joined up with his dad in 2001.
Here's a set of Shadow Rods...
Here's a set of Shadow Rods two-piece 'rails in Ionia's jigs.
After team Lesky was up and running, the duo continued refining a unique approach to chassis fabrication, one in which modifications matched the frame's factory architecture. While most builders were using some sort of tubing to build crossmembers, Ionia's frames had X- and K-members that were folded from flat stock and had rivets, and stamped and flared holes-features that made them look like they were in the 'rails from the factory. That particular approach, and the attention to detail they lavish on everything that leaves the shop, began to catch the eye of many enthusiasts and has resulted in Ionia turning out several high-profile cars, including Geoff Skene's '32 that graced SRM's July 2007 cover.
While the Leskys have certainly proved they can build a turnkey car like the best of them, they haven't forgotten what it's like for those building a car at home in the garage either. To that end, they can help by supplying a little touch of Ionia to make your car cooler-everything from crossmembers, X-members, and boxing plates to a complete A-V8 or '32 chassis.
The joint in the two-piece...
The joint in the two-piece framerails is reinforced by a formed backing plate, or fishplate, to which they are often referred.
On the subject of framerails, one of the most revolutionary products to come along in a while are the two-piece Deuce 'rails from Shadow Rods. Built in two sections that are welded together, they look original once the welding is done, but the real beauty lies in the fact that the multi-piece design means they're small enough to be shipped by means other than truck freight, so they can come to your front door via UPS. And now, thanks to the Ionia crew, these 'rails can come to you pinched and modified for either '28-29 or '30-31 Model A bodies. In addition, instructions for modifying the rear portion of the 'rails for an A-body are included, or they'll do that for you too.
Not long ago, our own Brian Brennan wandered by Ionia to see what the Leskys were up to. Along with a host of other projects, there were a pair of Shadow Rods '32 framerails being modified for an A using the very same components that can come to your door in kit form or a complete chassis. Take a look at the possibilities, and if you hurry you can still update that Christmas wish list.
With the fishplate in place...
With the fishplate in place on the inside of the 'rails, they are clamped together in preparation for welding.
This is the reinforcement...
This is the reinforcement from the inside of the 'rail. Note how tightly it fits and that there is room on the 'rail's flange for welding.
Another trick the Leskys use...
Another trick the Leskys use in Deuce frames is this special flattened Model A front crossmember from the Hot Rod Garage. An A crossmember in a '32 provides a 1-inch drop; this crossmember provides two.c
When a front crossmember is...
When a front crossmember is installed at the shop, tabs are added and holes are drilled into the outside of the 'rails and the crossmember's flange so rivets can be installed for a factory look.
Along with the rivet holes,...
Along with the rivet holes, four additional holes are drilled into the 'rails so the crossmember can be welded to the 'rails. However, those holes are not drilled in the crossmember.
For extra strength, the crossmember...
For extra strength, the crossmember is secured to the 'rails through the four holes with what are called rosette welds.
This is how the welds should...
This is how the welds should look once they are ground smooth.
Rivets are installed for that...
Rivets are installed for that factory look, and they really do add strength as well.
The rivets are heated prior...
The rivets are heated prior to installation to make peening the ends easier.
The ends of the rivets are...
The ends of the rivets are flattened with a special tool once they are in place.
Here's the finished crossmember...
Here's the finished crossmember reinforcement riveted in place. Looks factory, doesn't it?
Ionia can also supply these...
Ionia can also supply these cool boxing plates. Not only do they have stamped holes, but the edges are also rolled for a factory look.
There are several ways to...
There are several ways to put a flat-bottomed A-body on a '32 frame with a "dip" in the middle of the top flanges of the frame.
Some modifications are in...
Some modifications are in order when an A-body sits flat on a '32 frame because stock Model A bodies sit on wood spacer blocks everywhere but the cowl.
Here's a cool little trick...
Here's a cool little trick the Leskys use: Small tabs are welded in place so the boxing plates will be set into the 'rails at uniform distances.
With the spacer blocks tacked...
With the spacer blocks tacked in place, installing the boxing plates is a simple matter of clamping them into position and welding them.
Here's a good look at the...
Here's a good look at the notch in the top of a '32 framerail to accommodate an A-body.
Some notching will be required...
Some notching will be required around the front crossmember to install the front boxing plates. A template is being made here.
This is the kind of detail...
This is the kind of detail for which Ionia has become known.
Ionia's X-members can be trimmed...
Ionia's X-members can be trimmed to fit a variety of frames and are available with cutouts to mount '39 Ford pedal assemblies.
The rounded edges on the punched...
The rounded edges on the punched holes can easily be seen when viewed from this side.
The X-member can be positioned...
The X-member can be positioned accordingly depending on the engine/transmission selection and placement.
Here, an X-member has been...
Here, an X-member has been installed; the transmission crossmember can be positioned as necessary. Note that the Deuce 'rails have been pinched ahead of the crossmember.
There is a variety of options...
There is a variety of options for the rear of A-V8 frames.
Available in what is essentially...
Available in what is essentially kit form, or completely welded together in their jig, the Ionia A-V8 frame is a solid foundation for a street rod.