How to Apply Lead - Get The Lead Out

With the surface area ready, Matt warmed the jar of tinning butter (then stirred its contents) with an oxyacetylene torch using a short flame with low heat to make it soft enough for brush application.

Matt first warmed the metal surface where the tinning butter would be applied, and then he brushed the product onto the surface using a disposable brush.

Every area receiving body solder must be properly tinned, and here we can see the completely tinned A-pillar and cowl awaiting the next step.

Once the tinning butter had set, Matt proceeded with a short flame to warm the surface area. With the area heated, he used #1 steel wool to wipe any excess product from the surface, from bottom to top, which left the area suitably tinned and ready for body solder.

Using a small Vise-Grip to handle the stick of body solder, Matt worked from bottom to top with a short flame to warm the body surface, following with the stick and applying the product in a left-to-right motion.

The A-pillar and cowl area looked like this once completed. It might be necessary to build up certain areas with additional solder as the job proceeds, depending on the need of the area being worked.

In order to properly spread or "paddle" the solder, Matt first coated the surface of the paddle with melted tallow (wax) so the softened solder would be easily moved on the applied surface.

Matt warmed the soldered area with a soft flame until it almost became liquefied, and then he began to paddle-shape the solder into place. It's a smart tip to take your time during this step to make sure the solder is properly pressed into place.

It might not win a beauty contest, but this is how the soldered area looked right before the cut-down phase began.

Wearing eye protectin and a heavy-duty respirator, Matt began knocking down the high spots and feathering the edges using a small air-driven grinder topped with a 50-grit disc.

The surface was starting to look a lot less intimidating after the first pass with a 50-grit disc. The solder is a snap to work with when using the right tools.

Matt then used a die grinder to start working the tight areas of the inner windshield frame to restore the original proportions of its gentle bottom curvature.

Matt worked with a number of hand files, including vixen, flat, and half-round styles, to cut through the solder and bring back the body lines on the A-pillar and cowl areas. Be sure to take your time with this step, because it's back to applying more solder if you over-cut or file.

To return some of the body lines, it's necessary to use many different types of tools to cut down certain areas. Here, Matt used a leading edge of a flat file to restore a body line at the windshield area base.

Laying a flat edge across the A-pillar gave Matt an indication of the work that still had to be done to get that plane completed. It takes time and a lot of finessing to get an area perfect.

Using a Sharpie, Matt marked off the areas he would need to file to return the contour to the A-pillar reveal area.

This close-up shows how Matt used his flat-faced file to gradually return the original body lines to the car, making the chop look like it was always there.

A number of passes with a flat file brought the A-pillar area to the point where only some fine finish work was needed.

Initially starting with 80-grit on the entire area, Matt changed to 150-grit to give the finish a nice, smooth feel and appearance.

Once all the sanding was completed, Matt followed through with a red scuff pad to complete the work to the surface.

Preparation for the final step required a mixture of warm water and baking soda to neutralize the acid that had built up on the worked surface area.

Removing any acidic residue from the surface, Matt used a bristle brush and worked the preparation well into the surface. A final clear-water wash and wipe with a clean, dry cloth completed the job.

The A-pillar and cowl area look downright bitchin' with the job wrapped up. As the bodywork cruises toward completion, the coupe's chassis phase is up next, so stay tuned as the team gears up to build a wicked spine for the Deuce.