The first step is deciding...
The first step is deciding the right amount to narrow the shell. I'm using a paper tracing from the grille shell here. This makes it easy to try out different arrangements. I've decided to narrow it 5 inches on the top, and 6 inches on the bottom. One of the problems of narrowing the shell this much is that it doesn't leave much of a peak at the top of the radiator opening. We'll address this shortly.
Last month we went through the process of chopping a 1932 Ford grille shell. For another example of how a grille shell can set a particular style for a car, look at some of the modified roadsters built lately, such as Chris Staneck's car that was on the cover of STREET RODDER (April 2010), or some of the cars built by Steve Grimes. On these cars, the grille shell has been radically narrowed, which gives them a lean, narrow, and serious race car-style look.
The work required for this modification is just a little more involved than the previous example, but still within reach for a beginning to mid-level metalworker. Some of the challenges are getting the contours on each side to match in the center, after removing a 5-inch strip, and regaining the distinctive peak at the top of the radiator opening. By following these photos, you'll see how to accomplish these goals.
Ron Covell has made a DVD that covers the work done in parts 1 and 2 of this series, showing the process of re-proportioning a '28 and a '32 Ford grille shell. Every step is shown in detail, with great close-up shots, and lots of clear commentary that brings out many of the fine points involved in doing high-quality metalwork.
The price of the DVD is $20, and you can order from Covell Creative Metalworking online at www.covell.biz, or contact them by telephone at (800) 747-4631.
This is a reproduction grille...
This is a reproduction grille shell from Speedway Motors. Knowing the dimensions the shell will be narrowed, I'm using a straightedge to lay out the cut lines on the top and bottom of the shell with a felt-tipped marker. All measurements are made from a carefully plotted centerline
A felt-tipped marker leaves...
A felt-tipped marker leaves a line too broad for an accurate cut, so I'm laying down strips of masking tape, and the cuts will just touch the edge of the tape.
The cuts are made with an...
The cuts are made with an abrasive cut-off wheel in a pneumatic die grinder. I'm guiding the disc very carefully along the edge of the tape.