Shadow Rods XL27 Roadster - From Buck To Finished Piece

Complicated parts can be fabricated by first making smaller sections then welding them together in a patchwork pattern. The pieces are constantly test-fit against the buck for accuracy.

Once a major section has been fabricated, it can be tack welded together-smaller pieces become bigger pieces and soon you have a track nose!

The top piece of the track nose is shown being worked on a Yoder power hammer. Master craftsmen can make the smallest adjustments on their machines to either get just enough curve pounded into a piece or to hammer welds flat.

The area for the grille opening can also begin to be trimmed, but not too much: it's easier to cut away than it is to add metal!

Vise grips clamp the different pieces together, and Cook notes where they can be trimmed before being tack-welded together.

Each section is fabbed then tack welded to the nose. The more intricate pieces (ones with many curves) are often made separately rather than trying to make one piece with multiple returns.

To aid in making the grille insert, another piece was fabricated out of aluminum on the Eckold machine to simulate the grille's shape.

Fit to the track nose, the grille panel can now be used as another pattern to help make the insert.

Here's the inside of the finished nose and the outside. Once the nose is finished they can move onto making the pattern for the custom radiator.