With the transition piece from the dash completed, Schmidt focused on the gradual sweeping flow needed to bridge this area to the door top. Working in the same fashion used to create the initial dash end mold, he proceeded with tape and plastic filler to design the transition atop the door. Using this as a guide, he selected a 4-foot section of 1-3/4-inch steel exhaust pipe to act as a solid base. After bending the pipe to match the factory curve of the door top, he marked it for trimming and where it needed to be split open to begin the shaping process. While anchored in a bench vise, he used an air-driven cutoff wheel to make the initial incision to split the pipe section open. Using an anchored flat dolly, Schmidt proceeded to open up the pipe by hammering both of the separated sides flat with a rubber hammer from front to back. This prevented the pipe section from becoming dented during the process. To open the pipe even further, he used a pair of duck-billed Vise-Grips parallel to each other to additionally stretch the section open. As the pipe changed its shape, Schmidt checked the section to the door top numerous times to ensure the curve to the top of the pipe did not become distorted. This is a gradual process that takes plenty of time to get right.

Once comfortable with the fit to the door top, it was time to begin forming the forward end (which will meet the dash filler piece) to add the needed graceful curves and form the transition. For this step, Schmidt used various anchored dollies to gradually stretch the steel while adding curves and depth through the use of a number of body hammers with different ends. Again, this is a process that takes time, working the steel and placing the filler piece atop the door countless times to aid in its shaping to create just the right contour.

Once satisfied with the overall shape, Schmidt first reinstalled the Sellers Equipped windshield and then marked the exterior of the new door top with masking tape to show a delicate sweep from fore to aft. He cut the excess metal off using a plasma cutter and ground the edges smooth with a small disc grinder. Wanting to achieve the correct contour for the inside curve of the door, a relief-cut was made using a disc grinder to the inner top edge and it was rolled inboard. Focusing on the inner portion of the door top, a masking tape line was run from the end of the dash filler piece rearward to follow a gradual tapered line. The door top was then removed, trimmed with a plasma cutter, and its edge ground smooth with a disc grinder. Knowing that interior panels would need an anchoring point, Schmidt marked a "fold-line" on the door top, which would need to be bent inward toward the door. Since this was a compound curve, to accomplish the bend a number of relief cuts were marked and carefully cut using an air-driven cutoff wheel with the piece in a bench vise. With the curve intact, Schmidt used a flat anvil secured in a bench vise to bend the tabs over to the correct angle. After test-fitting the door top in place, it was again removed for the tabs to be MIG welded together. It's imperative to allow ample cooling between the welds so as to not distort the steel. A disc grinder was used to smooth out all of the finished welds. Once a few remaining filler pieces were fashioned and added to the front inside top hinge area of the door, the new door top was welded into place and all welds were ground smooth with a disc grinder topped with a 50-grit disc. The completed job added newfound personality to the interior of the Model A by incorporating plenty of sleek styling with the flow of the '32 Ford dash into the door tops.

SOURCE
Rolling Bones Hot Rod Shop
518-893-2646
http://www.rollingboneshotrodsho
p.com/
Sellers Equipped
www.hubgarage.com/mygarage/selle
rsequipped
Brookville Roadster
937-833-4605
http://www.brookvilleroadster.co
m