Similar to the plastic mold...
Similar to the plastic mold of the dash, one was also crafted for the door top. The steel filler panel is being compared to the molded unit for continued fabrication in the shaping stage. The guide line marks where the door top contour will meet the corner of the dash.
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.
With a variety of anvils and...
With a variety of anvils and hammers, reshape the steel pipe to form the proper contour for the top of the door as it transitions to the end of the dash. Take your time to achieve just the right lines.
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.
This look-down shot lets you...
This look-down shot lets you see how the original steel pipe has been reworked to curve and flow into the filler panel at the end of the dash.
To achieve the right contour...
To achieve the right contour for the inside curve of the door, a relief cut was added to the inner top edge and rolled inboard since the metal could not be stretched any further.
Once the proper shape was...
Once the proper shape was attained, the relief cut was MIG welded and then ground smooth using a small air-driven disc grinder.
The new door top was laid...
The new door top was laid into place and marked for additional trimming to establish the correct gap between the dash filler panel extension and the door top.
With the Sellers Equipped...
With the Sellers Equipped windshield in place and the new door top taped into position, the final exterior trim is determined. A tape line is used to establish the cut needed. Remove the piece and use a plasma cutter to trim the area followed by a disc grinder to clean up the edge.
From inside the car with the...
From inside the car with the new door top in place, masking tape was used to establish a gradual tapered line from the front of the door rearward. The piece was then removed and trimmed using a plasma cutter. Note the marked fold line where the steel will need to be modified for future interior panel needs.
In order to bend the steel...
In order to bend the steel on the fold line with its compound curve, a number of relief-cuts were made to the panel using an air-driven cut-off wheel. With the panel back in place, it's easy to see that the curve is intact.
The relief cuts created a...
The relief cuts created a 3/16-inch gap to allow interior panels to be tucked into place. With the panel removed and a secured anvil, a vise and hammer were used to properly bend the relief-cut tabs over at the correct angle.
With all final finessing complete,...
With all final finessing complete, a MIG welder was used to weld all of the gaps followed by a disc grinder to smooth out the completed surface.
The one remaining area needing...
The one remaining area needing attention was the front hinge side of the door where the new door top ended since the spot was wide open.
It's easy to see just how...
It's easy to see just how dramatic the completed changes are. Propelling the original basic lines into those of a graceful sweep gives the car a newfound raciness, flowing perfectly with the Sellers Equipped windshield and Brookville '32 Ford dash.
A small filler piece was crafted...
A small filler piece was crafted using 22-gauge steel to close the area. The driver's door is shown alongside as a comparison. The pieces were MIG-welded into place and ground smooth using small die grinders.