OldCars

AutoRestorationGuideVol.II

AdviceandHow-ToProjectsforYourCollectorCar

CONTENTSFOREWORD

SECTIONONE:EXTERIORSFenderFitmentFordHingesFitmentFixPatchPanels101HangingDoors:HowtheProsDoIt1962ImpalaSSRevival:Part11962ImpalaSSRevival:Part2PinstripingMadeEasy

SECTIONTWO:INTERIORSCarpetCuttingUpholstery101:RecoveringanArmrest

SECTIONTHREE:MECHANICALWheelBearingHubsinaDaimlerBleedingBrakestheRightWayCrateEngineAdviceEngineRestorationFordGAAEngineRestorationBrakeBoosterReplacementFinickyFuelGaugesAirConditioningSystemBasics

SECTIONFOUR:GENERALShopStop:MotionPerformanceShopStop:Ken’sKlassicsShopStop:CatchingUpWith‘TheBoss’Man:BobPerkinsSalvageYardStop:CTCAutoRanchSalvageYardStop:WollerAutoParts

RestoringVintageLicensePlatesNewProductsFortheRestorerTipsforTraileringaVehicleBarnFindAdviceBlastingCabinetBasicsOctaneByTheNumbers

COPYRIGHT

FOREWORDItisforalltheoldcarhobbyistsoutthereturningtheirownwrenchesandbloodyingtheirownknucklesthatweofferthesecondvolumeof“OldCarsWeekly’sAutoRestorationGuide.”Insideweofferrestorationadviceandhow-toinformationfromavarietyofprofessionalsources,aswellasfromregularJoeswhojusthappentoknowalotaboutfixingandrestoringvintagecars.Wegetinspiredhearingallthestoriesfromcarownersabouttheirstruggles

andtriumphswiththeirantiquevehicles.Hopefully,thisbooksuppliesalittleinspirationinreturn.

—FromthestaffatOldCarsWeeklyandOldCarsReportPriceGuide

SECTIONONE

EXTERIORS

FITTINGFENDERSSavedbyshims:Howlittlethingscanmakebigdifferences

StoryandphotosbyRotten“Rodney”BaumanItwasalonghaul,butthislong-ongoing’31CadillacV-12convertiblecoupeprojectwasarunnerbythetimewewerereadytopaintandcompletethefinalinstallationofthefenders.Thebodywasresplendentingreenwithblackreveals.Thefendersandapronswouldsoonbeblackaswell.Wehadatrimmerworkingonthecarandthepainterinmewasprettyprotectiveattimeslikethese.However,asitturnedout,ourtrimmerofchoicewasactuallyquiteconscientious

andhedidabitchingjobwhileIwaspaintinglittlepiecesandworkingthefenders.BeforeIputthefendersincolor,Iwantedtoverifythattheyweregoingtofit

aswellastherestofthecar.Weworkedhardtofitthegapsonthisoldwood-framedbody.Thefendershadbeenfittothecarbefore,butthatwasintheearlystagesoftherestorationandtheyhadbeenhammeredalotsincethen.So,adouble-checkforfenderfitmentwasgoodinsurancewhiletheywerestillinfirst-roundprimer-surfacer.Beforeanyseriousscrutinizingtookplace,andbeforeanymeasurementswere

recorded,wecheckedforeventireinflationallthewayaround.Ameasuringstickconfirmedthatthepassenger’ssideframehornwasalittleclosertotheshopfloorthantheleft.Aweakspringcouldhavebeentheculprit,butthatcouldbeaddressedatalaterdate.Forthisfenderfitmentinspection,weneededtheframelevel,whichwetemporarilyaccomplishedwithalittlehelpfromalevel,ameasuringstickandasmallhydraulicbottlejack.

Inthebeginning,itwasbusinessasusual.Withthecar’sweightonitssuspensionandeventireinflation,abottlejackwaspositionedunderthesaggingpassenger’ssideframe

horn.Thenalonglevelwaslaidacrosstheshanksoftheupperbumperstuds.

Someminorlevelingadjustmentshadtobemade.Thebottlejackhelpedthroughthisphasesowecoulddiagnosethesourceofthesagwiththefenderssafelyremovedfrom

thecar.

Aftersomeadjustment,weweresatisfiedthattheframewaslevel.However,justoutofviewatthefrontfendertips,wealreadysawthetwistinthefender.Thesefendersarevery

strong.It’snotliketheycanbebentaroundlikeasame-vintageFord.

Whatstartedoutasastandard,straight-forwardproceduretookasurprisingtwistintheformofatwisteddriver’ssidefrontfender.Inshortorder,Iembarkeduponanemotionalrollercoasterridewhichtookalotoutofthelil’oldautorestorerinme.

Withthecentersofthetires’treadsgun-sighted,themeasuringstickdidn’tlie.Althoughtheframewasnowlevel,therewasstillahalf-inchdifferenceinheightfromtheshopfloortothefenderbead.Evenwithoutthemeasuringstick,theproblemwasobvious,andatthis

point,theshapesofthefendertipsalsoappearedtovary.

Asluckwouldhaveit,thesefenderbracesonlybolttothesidesoftheframe.Therearefourboltsinafairlysquarearrangement.Itappearedapairofshimsaddedattheupperboltsbetweentheleftbraceandframerailwereallthatwasneededtolowerthefender.

Here’sjustanotherexampleofhowlittlethingscanmakebigdifferences.Inthisparticularinstance,twosmall(1/8-inch-thick)Au-ve-cobodyshimsallbutcuredthefenderfitment

issue.

Thefendersnowlookedasthoughtheycouldhavebeenstampedbythesamemanufacturer.Theangleatthebeadhasalsoimprovedvisuallyandfromhere,Ihadlittle

doubtthatI’dbeabletodialtheminfurtherduringfinalassembly.

Youcanonlydosomuchwithaboxofshims,butthistimewe’regettingoffeasy,thankstoarestlessnight’ssleepandAu-ve-coProducts’shims.

Whatyou’reabouttowitnessmademesickatfirstglance.So,Idevouredalargehabanero,anchovyandheadcheesepizza,hadabeerandcalleditanight.Theperplexingproblem’ssimplesolutioncametomeinawarpedandtwisteddream—awarped’n’twistedfenderdream.

SourceAu-ve-coProductswww.auveco.com

BACKTRACKIN’FORGAPSAnout-of-sequencesolutionforbadpanelalignment

Withthedoorssafelyremovedandsecuredto500-pound-capacityAstroPneumatic(Model#APT-55703)portableworkstandsfromSummitRacingEquipment,TroyBowdencanturnhisattentiontotheneglecteddoorhingescausingtheill-fittingdoors.Removalofthe

doorswasn’teasy,evenwithanimpactdriver,theleading-brandpenetrantandfinallytheapplicationofheat.Judgingbytheamountofrustunderthehingesandaroundthe

threadsofeachoftheoriginalPhillipsscrews,wecanbefairlycertainthatthisisthefirsttimethey’vebeendisturbed.

By‘Rotten’RodneyBaumanInanybodyandpaintshop,panelalignmentcanbechallenging,andmoreoftenthannot,alsofrustrating.Thisholdsespeciallytruewith’50sAmericancars.Generallyspeaking,panelsoncarsofthe’50sdidn’treallyfitwell,evenwhentheywerenew.Today’sconscientiousrestorers,however,tendtoexhibitelevatedstandards.InEscondido,Calif.,HotRods&CustomStuff(HR&CS)isperhapsbest

knownforitslongstringofhigh-profilehotrodhomers,buttheshopalsoassistsrestorerswithallphasesoftheirproject.Frommediablastingtopainting,

polishingandevenpinstriping,HR&CSistrulyaone-stop-shop.Forexample,aproject’spanelalignmentissquaredawayinthebodydepartment,beforetheprojectispassedalongforpaint.Sadly,notall“restorers”adheretotheprocess,andJimSartor’srare1950FordCrestlinerexemplifiesthatstatement.ThisistheCrestliner’ssecondvisit.Itrolledinlookingprettymuchasit

appearshere,butwithparticularlyill-fittingdoors.Amonthorsoago,thecarwasbroughtinaforafresheningofits8BAflathead,aswellasasorting-outofsomehandlingissues.Nowthatithasreturnedforits500-milecheckup,thedecisionwasmadetocorrecttheoffendingdoorgapsviaitshinges,whichhadbeenthemaindetractiontothecar’svisualappeal.

Bythistime,thewornpinsandholesofthedoorhingeshavealreadyundergonemajorreconstructivesurgery,whichbeganinabeadblastingcabinet.

Onehingepininparticularwasactuallybrokenandrustedinposition,soitwasonlygoingalongfortheride.

FordMotorCo.’sPhillipsscrewswillbereplacedforthebetterstainless-steelsocket-headedfasteners.

Withthethreadsappropriatelycleanedandlubricated,Bowdenpreparestore-hangandadjusttheFord’sdoorsusingawell-paddedfloorjack(doorjack?)andafairamountof3M

maskingtapeatthepaneledgestopreventscratchingandchippingthepaint.

Allfinished—astraight-forwardfixforapreviouslyignoredissuethatreallyshouldhavebeenaddressedpriortopaint.

Theidealtimeforpanelalignmentprocedurestobeginisnotafterpaint,buttheHR&CSbody’n’paintpro,TroyBowdenhasbeendownthisol’familiarroadbefore.Inthebusiness,Troyiswhatwecalla“combinationman.”Well-versedinbodyandpaintshopoperations,Bowdenpossessesafullbagoftricks,nottheleastofwhichincludesexpertpanelalignmentability.Here,ashehasmanytimesinthepast,BowdenwillbeginbyprotectingtheCrestliner’spre-existingfinish,justasifithadcomefromhisowngun,ashebeginsrestoringtheCrestliner’shingesforbetterdoorfit.Attheendofthissession,anothershop’sworkwillberefined,andnoone(exceptforus)willbethewiser.

HotRods&CustomStuff

www.hotrodscustomstuff.com

SummitRacingEquipmentwww.summitracing.com

TUNABLETENSIONAnol’fashionedfitmentfix

StoryandphotosbyRotten“Rodney”BaumanGappin’doesn’tjusthappen.Whenabodyonarotisseriemustbecomereacquaintedwiththeframerailstowhichitbelongs,orwhennewmountingpadsandaboxfullofshimsaren’tenoughtosquarethingsup,you’lllikelytwistpanelsandcutpartstogetagoodgap.Inordertoachievepanelalignmentwithuniformgaps,bepreparedtodowhat’snecessaryandthinkoutsidetheboxo’shims.

Wood-framedbodiesareparticularlytrickyandsometimesactasiftheyhavememoriesormindsoftheirown.Surprisingly,however,this1931Cadillacconvertiblecoupebodyhashelditsshapequitewell,bothovertheyearsandduringitsrestoration.Attheproject’searlybeginning,mymetal-fabricatingwife(Mrs.Rotten)weldedsomebolt-inbracingtokeepthedoorjambsproperlyspacedduringthetimethatthebodywouldbeofftheframe.Backedbyanadditionalbolt-inX-member,thebracingdiditsjob.Wealsoreceivedararebreak,asthemajorityofthiscar’soriginalwoodenbodystructurewasstillsolidandstrong.DuringtheoldCadillac’sdisassembly,atwo-postliftwasusedtoraisethe

bodyasthechassiswasrolledoutfrombeneathandtherotisserierolledinitsplace.Withtwolengthsof4x4,oneoneachsidebetweentheadjustablerotisserieandthebody’swoodenfloor,thebodywasboltedtight.Duringthefrightening“frametolifttorotisserie”procedure,Iheardneitheracreeknorasqueak,andI’mheretotestifythatIwitnessednobodyflex.Sure,thestepswerewellthoughtoutandthoughtfullyexecuted,butstill,there’snodenyingthatluckwasafactor—atleasttothatpoint.Asluckwouldinevitablyhaveit,luckranout.Duringthecar’sfinal

assembly,thedriver’ssidedoortookabizarretwistandbegantosag.Thedoorfitbefore.Infact,I’dalreadygonetogreatlengthstomakeitfitwhenthebodywentbackonthechassisafterI’ddoneallIcouldwithshims.Monthsago,whenthebodywassnugglyplacedwhereitwastostay,I’daddedandsubtractedmetalattheedgesofbothdoorstogetthegapsIwasafter.Mysteriously,afterthepaintwork,thingswerenotasIrecalled.Thatwasoneofthose“walkaway”days,butwhentheroostercrowedthenextmorning,onepossiblesolutionhaddawned.Itworkedforme.Itcouldworkforyoutoo.Here’show:

Thisbodywasshimmedasgoodaspossible,andthebodyboltsweretight.Thedoorssaggedbadly,soadditionalshimsweremadeandinsertedatthehinge-to-doorattachment

points.Spacingonlythedoor’ssideofthehingekepthingegeometryintact,butunfortunately,itwidenedthereardoorgap.Metalhasbeenaddedthere.

Bythistime,finishbodyworkofthedoorswascomplete.Primer-surfacerwasappliedandthedoorswerehungonceagainsothatlongboarding/fairingoperationscanbegin.Sofar,allsandingwasdonedry,andtherewerenosignificanttemperaturefluctuationsinthis

stall.Theproblemdoorstillfitthesame.

Eventhoughthepaintertookprecautionstokeepthewoodenstructuredryduringwetprep,cuttingandbuffing,theshapeofthisdoorchangedsomewherealongtheway.Itnowsaggedwithanoutwardtwisttowardthebottom.Infact,contactwasmadeinthefront-

lowerportionofthesejambs.

Thesituationworsenedwiththeweightgainsoftheglassandregulator.Ifiguredintheirweightbefore,butmuchhaschanged.Whatwe’reabouttotryisnotanoriginalidea.Inolderwreckin’yards,I’veseencrudelycobbledtensionersmadefromchains,knotted

cablesandsuch.Attimeslikethese,whathavewegottolose?

Ashoppingspreeatthelocalhardwarestorerenderedanicelittleturnbuckle.Therewasalengthofstrapsteelintheshop’sscrapmetalbin.Ifthingswentaccordingtoplan,we

wereonlyafewwoodscrewsawayfromhavingourmaterialsgathered.Thefirststepwastoopentheturnbuckle’seyesjustatadortwo.

Notyetknowingwhereweweregoing,atightstretchofmaskingtapeprovidedtheguidefordeterminingthepathofleastresistance.Therewereanumberofprotrudingmechanismsandfastenersthatwepreferredtosteerclearof,ifatallpossible.

Oncethespotsweremarked,oursteelstrapscrapswereontheirwaytobecominganadjustabledoortensioner.Providingitdiditsjobaswehopeditwould,arouterwouldbeusedtocreateaslotforthesepiecestolayflushinthedoor’swoodeninnerstructure.

Then,ourtensionerwouldnoteventuallyinterferewiththeinteriortrimpanel.

Sofar,thisisonlyatest.Beforeanyextraholesweredrilled,weneededtoexaminehowtheadditionalhardwarelinedupwiththesurroundingobstacles.Asitworkedout,thesteelstrap’sscrewholesrequiredastaggeredarrangementsoasnottocollidewithFleetwood’s

preexistingfasteners.

AlthoughI’veneverownedacomplete,unbrokensetoffancydrillstops,Icanusuallyfindalengthofrubberhosethatwilldothesamejobaboutaswell.Thewoodintheseold

doorswasveryhard,sothedrillstopdemonstrationmaynotbecompletelynecessary,butIcouldn’tresist.

Whilewe’reatit,here’salittletrickIlearnedfrommycoworker,wholearnedthesametrickfromhisgrandfather,anoldwoodworker.Hardwoodwillsnapsoftwoodscrews,soa

quickbrushofthethreadsoverabarofsoapislikeanounceofprevention.

Duringinitialtensionertesting,wequicklydiscoveredthattheeyesoftheturnbuckleshouldbeweldedclosedoncethey’vepassedthroughthedrilledholesinthestraps.Initsstock,pre-weldedform,theturnbucklewasn’tstrongenoughtowithstandtuning—the

eyesstraightenedrightout.

Withtheturnbuckle’seyesweldedclosed,itbegantomakesensethatthisheavydoorcouldusealittlehelpfromascissorjack.Withthejackdoingtheheavylifting,the

turnbucklecouldbeadjustedeasilywithoutaskingtoomuchofit.Ittookseveralattempts,butthehappyspotwaslocated.Thedoorfitnicely,withoutcontactinthejambs.

Nowthatwewerecertainthatouradjustabledoortensionerwouldindeeddothetrick,thefunctionalmockupwaspulledbackoffsothataflush-fitslotcouldbemade.

Backinthegroove:Oncefine-tuned,thecenter-mostwoodscrewswereinstalledlast.Wemayneverknowforsurewhatdistortedthisdoor,butwe’resatisfiednowthatit’sbeencompensatedfor.Ifitshouldactupinthefuture,aminoradjustmentofthesoon-to-be

cleverlyconcealedturnbucklecouldagainbethecure.

Gappin’don’tjusthappen.Truthbetold,thisjobbeatmeupprettygood,butthiswasnota“walkaway”day.Onceagain,there’snooriginalthinkinggoingonhere.It’saglorifiedversionofsomethingI’veseeninoldwreckingyards,perhapsroughlybasedonanold

coachbuilder’strick.Nomatter.Attimessuchasthese,whathavewegottolose?

PATCHPANELSMADEEASYRustbustingona‘37Chevyschoolbus

This1937ChevroletschoolbuswasticketedforacompleterestorationatFastFreddie’sRodshopinEauClaire,Wis.Longbeforeitwouldbereadyforanypassengers,thebus

wouldneedsomeextensiverustrepair.

ByBrianEarnestWhenFastFreddie’sRodShopgotachancetorenovateandcustomizea1937Chevroletschoolbus,shopownerFredKappusJr.knewitcouldbeoneofthe

morefunprojectshisshophadevertakenon.Healsoknewitcouldbeoneofthemostchallenging.Therearen’talotofhow-tomanualsorblueprintsfloatingaroundoutlining

howtorestorea75-year-oldbus.Andthiskidhaulerwasgoingtoneedprettymucheverything:frame,drivetrain,paint,bodywork,interior—theworks.

Thetoolsneededforapatchpanel:ARoll-Locksandingdisc,cuttingtool,airdusterandstonewheel.

Thepatchpaneliscutoutonasheetmetalsheer.“Giveyourselfanextraincharoundtheareayouarefixing,thenalotoftimeswe’lljustuseapieceoftagboardandthentraceit

outandtransferittometalwithaSharpie,”Kappussaid.

“TheschoolbuscamefromtheguyswhohaveStudentTransitinEauClaire,Wis.,andtheyruntheschoolbussystem.They’vehadthebussincethe’60s,it’sbeeninthefamily,andtheyarekindoflookingtodoatributetothebus,”Kappussaid.“Theyarelookingtodoamodernizedversionandmakeitalotmoreuserfriendlyandalotmoredrivable.Itcameinandhadtheoriginalthree-speedinitandastraight-six,sobasicallywhatwe’regoingtodoisachassisswapthatbringsamodernchassisintoit.Powersteeringandbrakes,independentsuspension,big-blockV-8init,overdrivetransmission.“Itwillhaveenoughpowertocruisearound.Doparades,whatevertheywant

todowithit.”Tobesure,therewouldbealotoftweaking,trouble-shootingand“makingit

uponthefly”momentsfortheFastFreddie’screwbeforetheretrobuswouldbereadyfortheroad,butonepartoftheprocessthatwasprettymuchastraight-forwardpropositionwastherust-repairneedsthebushad.Thegoodnewsisthat

mostofthebadspotsonthebodywereinflatareas,makingrepairsrelativelyeasy.Thebadnewsisthattherewerequiteafewspotsthatneededattention,meaningthereweregoingtobeanumberofpatchpanelsthatwouldneedtobefabricated,weldedinplaceandgroundsmooth.The1937Chevybusbodyactuallyhasinnerandoutersheetmetal.Belowthe

floorofthebushangswhatisreallynothingmorethanabigapronorfenderskirtthatrunsalongthesidesofthebody.Bothlayershadrustissues.Inthiscase,theFastFreddie’screwwasstartingwiththeoutsidesheetmetal.Foraprofessionalrestorationshop,makingflatpatchpanelswithoutmuchfor

contoursortrickycurvesisprettymuch“BodyRestoration101.”“Onascaleof1to10,thisisabouta1.Thisiseverydayworkthatwedo,”Kappussaid.“Thisisthestartingpoint.Thisissomethingthatprettymuchanybodywithacutoffwheel,agrinderandaweldercanachieveinanafternoon.Thisisaverybasicrustrepair.“We’regoingtofocusonaparticularlyrustysectionofthebodyofthebus.

We’regoingtocutthatbadspotoutandreplaceitwithanicecleansheetofbrandnewsteel.It’llbe18-gaugecold-rolledsteel.“Basicallythefirststepistoidentifytheworstoftherottedareas,cutouta

rectangularpieceinthisparticularcasetomakeiteasiertopatch,thencutoutapiecethatfitsthathole,thenusesomeweld-throughprimeronthebacksideofthepanel,theinsiderockerpanel,soyouprotectthatbaremetal.”Thereplacementpatchisfirsttack-weldedinplace,thenthetacksarefilledin

withafinishweldallthewayaroundthepatch.TheweldsarethengrounddownwithastonewheelgrinderandfinishedwithaRoll-Locksander—either36-or80-grit,orboth.“Thisisasimplerepair,”Kappussaid.“Youdoneedtoknowhowtooperatea

welder,ofcourse,anddoneedtoknowhowtogetyourheatrangeandwirespeedsetproperlyforthegaugeofpanelthatyou’reworkingon.Inthiscasewe’regoingtocutouttheoldpanel,andwhenweputinthenewpanel,we’re

goingtobutt-welditinsoit’saniceflattransition.Afterwegrinditdown,youwon’tbeabletotellwe’verepairedthatarea.“Theprocessandtechniquewillbethesame[regardlessofthevehicle],it’s

justthelevelofdifficultychangesdependingonifit’sacompoundcurve,iftherearebodylinesinvolvedintherustrepair.Itcangowayupindifficultyfromhere,butthisisthemostbasic.”

Arectangularpatchwillbeplacedoverthisrustedarea.Inthiscase,apieceoftagboardwasusedasatemplate,whichwasthentransferredtoapieceof18-gaugecoldrolledsteel.Acuttingwheelisusedtocutoutthebadmetalontheoutsidesheetmetalofthebus.Inthiscase,thereisalsoaninsiderockerpanel,or“fenderskirt”thatwillhavetobe

addressed.

Theoutsidesheetmetaliscutawayandremoved.ThebusalsohasaninsidemetalskirtthatwillbecutawaywithaSawzall-typecuttingtool.

Magnetsareusedtoholdthepatchpanelinplacewhileitistackwelded.TheinitialweldsaremadeseveralinchesapartbyFastFreddie’sbodymanPeterSchnoor.Hethenweldsallthewayaroundthepanel,alternatinglocationssothemetaldoesn’tbecomeoverheated.Compressedairisusedimmediatelyaftereachweldto“purge”theweldandkeepwarpingtoaminimum.“Youcantellwhenitgetsjustalittletoohot,andwhenyouhititwithcoldair,youcanactuallywatchitpullbackout,”Schnoornoted.“Onanopenpanellikethis,

you’realwaysgoingtohavealittlebitofwarpingorshrinkage,butit’snicetotrytocontrolitasmuchaspossible.”

Thetackweldsarethenconnectedbyshortbeadsuntiltheentireareahasbeenfilledin.Schnoormovestoanewspotaftereveryweldsooneareadoesnotbecomeoverheated.“IskiptoadifferentspoteverytimejusttogiveittimetocooldownandsoI’mnotthrowingheatontopofheatinonearea.I’lljustkeepkindoffollowingitaroundandfillingitinasI

go.”

Oncetheweldiscomplete,astonewheelisusedtotakeofftheexcessmaterialandgrindthepatchflat.Therustisgonefromthisareaandit’sreadyforprimerandbodywork.

“We’llputDuraglasoverittofillinwhereit’sbeenwelded.Duraglasisagoodfilleranditkeepsmoistureout,”Schnoorsaid.“Thenwe’llputanypolyesterfillerthatweneedover

that.”

A‘56MERCGETSITSDOORSBACK

Tipsandtrickstomakeyournextdoorassemblyeasier

This1956Mercuryhardtophasbeencompletelytorndown.Oneofthefirststepsinthere-assemblyisdroppingtheshiny,freshlypaintedbodyshellontheequallyshinyframe.The

nextstepwillbetohangthedoors.

ByBrianEarnestMountingdoorhingesandhangingdoorsisoneofthoserestorationstepsthatprofessionals—suchastheguysatKen’sKlassicsinMuscoda,Wis.—make

lookeasy.Butasmanynovicescanattest,itcanbeafrustratingjob,especiallyforfirst-timers,andfroughtwithtrial-and-errorlearning.“Onascaleof1to10,it’sprobablya71/2,”chuckledT.J.Krueger,theshop

foremanatKen’sKlassics.Kruegerhelpedhangthedoorsonthe1956Mercuryshownintheaccompanyingphotos.“It’salottougherthanitlookstogetthedooradjustedright.Alotofguyswillputthewholedooron,andthey’lllineitallup,thenthey’llputtheglassandeverythinginanditwillsagaboutaquarterofaninchtoahalfanincheven,becauseofalltheweightoftheglass,thewindowregulator,thedoorpanel.

Adoordollysecurelyholdsthedoorandcanmakehangingdoorsaone-manjob.

“Soyouhavetokindofcompensatewhenyouputthedooronandit’ssomethingyoukindofjustgetusedtodoingwhenyoudoitenoughtimes.Youalwayswanttohaveitatleastaquarterofaninchhighattheback.Soyourgapwillkindofappearpie-shaped,fromthedoortotherocker,andthenonceeverythingisin,itlatchesdownwhereitshould.”Thereisnouniversalmethodforhangingdoors,butfollowingisabrief

tutorialonhowKen’sKlassicshandledthedoorsonthisMercury.

Thedoordollyisusedtoliftthedoortothecorrectheightandrollthedoorintoplacesoitcanbemountedonthetwohingesthathavealsobeenremovedandpainted.“You’reeliminatinganotherguy’slaborandnowyoucanraiseit,lowerit,moveitinandoutby

yourself.Whenit’sinrawsteel(notpaintedyet),thisthingisreallyhandy.Youdon’thavetoworryaboutthedoorbangingoffthecowlandscratchinganythingbecauseit’salljustrawmetal.Butitisatime-saver,forashopanyway.Thisdollyisreallyanicethingtohaveforashop,”saidKen’sKlassicsshopforemanT.J.Krueger.“Thenyoucan’tblameyour

buddyforhelpingyouputadooronandchippingsomething.”

ThebeefyoriginalhingesweresavedoffthisMerc.Thebaseofthehingewillbemountedwithfourboltsonthecowl,withthedoorflangeneedingthreeboltstosecurethedooritself.“Alotoftimeswe’llreplace[thehinges],orwe’llreplacethepinsandbushings,”Kruegersaid.“Theseactuallywereprettynice,butinthe‘60scars,theyworeoutfaster.

The‘50sstuffwasbuiltprettywell.”

Thedoorjambandbottomofthedooropeningarebothprotectedwithmaskingtapebeforeanyfittingtakesplace.Tapeisalsowrappedaroundanysocketsthatwillbeusedto

reducethechancesofknockinganypaintoffthehingesandhingebolts.

Thehingesareheldinplacewithtwoboltsinsidethecowlandtwoontheoutside.Theboltsareturnedonlyasfarasnecessarytokeepthehingeinplace.

Oncethehingehasbeensecuredtothecowl,theflangecanbefittedtothedoor.Theinsideboltsinthephotoatleftcanbeseenextendingoutthroughthecowl.“Youalwayswanttoeventhehingesandhavethehingesallthewayupandallthewayoutatfirst,andjustalittlebitloose,”Kruegersaid.“Youdon’tcrankanythingdowntightatfirst.That’showyoustripthreadsout,especiallyifyouaregoingtobeadjustingitalot.Ifyoucrankitdowntighteverytimeyou’rejustgoingtostripthethreads,thenyou’regoingtohavea

mess.”

Afterthetophingeisset,thebottomhingeisinstalledinasimilarfashion.Thegoalatthispointittohangthedoorslightlyhighinthebackcorner—atleast1/4inchhigherthanflushwiththetopoftherearquarterpanel.Thephotoatrightshowsthetwoedgesareeven,meaningthedoorstillneedstobeadjusted.Theweightofthedoorskin,glass,

windowregulatorandotherhardwarewilldropthedoorslightlyandhelpeventhingsup.

Theboltsonthedoorflangesareloosenedandthedoorisadjustedslightlyupwardbypullinguponthebackofthedoorandre-tighteningthebolts.It’seasiestwithtwopeople.

Thedoorisnowproperlyadjusted—roughly1/4inchabovethetopofthequarterpanel.

1962IMPALASSREVIVAL:METAL

Bodyrepairsandrestoration,fromthegroundup

ByKenStadelePhotosbyKen’sKlassicsLocatedoffthebeatenpathintheruralcountrysideofsouthwesternWisconsinisKen’sKlassics,atop-shelfrestorationshopnearthetinytownofMuscoda.Ken’sKlassicshasbeenaroundformorethanthreedecadesandhasmadeareputationrestoringhigh-endclassics—Pierce-Arrow,Packard,Cord,Auburn,Porsche,Cadillac,Ferrari—younameit,it’sprobablybeenthroughKen’sdoors.TheshopgainedareputationearlyforitsworkonseveralPierce-Arrow

projects,butownerKenStadeletakesonallkindsofprojects,fromvintagemuscle,to1950sfavorites,totrucks,resto-modsandhotrods.Mostoftheprojectsinvolveatotalground-uprestoration,andthatwasthecasewitha1962ChevroletImpalaSStheshoptookonthisyear.

Westartedwitha1962ImpalaSStwo-doorhardtop,butthecustomer’scarwasreallyrusty,soIsuggestedthatwegetbetterstartingmaterial.WefoundoneinApache

Junction,Ariz.SoweboughtthatoffeBayandhadittraileredhere,anditwasamuchbetterrust-freecar,anditwascomplete.

Theprojectvehiclewasasolidbutweather-beatenhardtopthatwaslocatedinArizona.ItwasimmediatelyticketedforacompleterebuiltthatwouldeventuallyincludeanewFerrariRedpaintjob,taninterior,newGMcratemotorandmodernautomaticfour-speedtranny.WehadStadelenarraratethemajorstepstheshophasundertakentogetthe

Impala’sexteriorreadyforfinalbodyworkandpaint.Ken’sKlassicstakesnoshortcutswhenitcomestomakingacarlookitsbest.

Thisisthewaythebodycamebackfromthesodablaster,niceandclean.Thesodablastingdidexposesomepreviousbodywork.

Wetorethecarallapartanddismantledit,soallofthesheetmetal,doors,mechanismsweretakenoutandtakeninforchemicalstripping.

Thesepartshavecomebackfromthechemicalstripperandareperfectlycleanandrust-free.

Ifwewouldnothavehadthevehicleblasted,wemaynothaveseenthesepinholes.Whenyougothatfar,thenyouexposethatkindofstuff.

Therewassomeperforationonthefloor,underneaththedriver’sfeet.Alotoftimesyougetintoacarwithmoistureonyourfeet,andalmostallcarpethasajutebackingthatholdsmoisture.It’snotuncommontogetsomethinareasthere,andthenonthe

passengerside,beneathwhereaheatercorehasleaked.

ThisareadidhaveBondo.Ithadmanyholesdrilledintoit.Thatwasverycommonyearsago—peoplewoulddrillholesinthebodytorepairadent,andtheBondowouldoozein

thereandholdon,butthatisnotdoneinaprofessionalshopanymore.

Withthiswafflematerial,youspotwelditonandyoucangrabontoitandpullthemetaloutinanumberofareas,andthat’sreallynicewithalongercreaselikethisonehad.It

looksliketheyranoveracurborsomethinglow.

Afterthecreaseispulled,thewafflestripiscutoffandthespotisgroundsmooth.

Thisisaholethatforsomereasonwascutintoasupportunderneath.That’sthewayitlookedbeforewepatchedit.

Twopiecesofmetalwereweldedtogetherandshapedtofittheholeandmakeapatch.

Afteratestfit,thepatchisweldedintoplaceandgroundsmooth.

Thisisn’tuncommononafactorypanel—thegasdoorlidreallydoesn’tfitthecontour.Alotoftimeswe’llre-radiusthedoorortheopeningsoit’saconsistentgapalltheway

around.

Herewe’reputtingthebodyshellbackontheframe.Thisistheproperwaytodoitbecauseifyou’redoinganyfloorpanwork,orgoingtocutoutanysection,thebodywon’ttwist.Youdon’twanttoweldapanelinwhenthebodyistwisted.We’reusingallbrand-newbodymounts.Wedidthisalittledifferentwiththeframe.Normally,youwouldleavetheframeinroughconditionsoyoudon’thavetoworryaboutgettinganydamageonit.

Wehaveitwrappedupwithpapertoprotectit.

Toreallydoaprofessionaljob,youwanttohavethedoorgapbethesameallthewayaroundthetop,sidesandbottom,andmanytimesvehiclesarejustnotthatgood.Wespendalotoftimeongettinggapsperfectbecausethat’swhatourcustomerswant.

Wetrytomakesurethefendersandhoodlineupandallthegapsarecorrect.Thethicknessofapaintstickisaboutwhatweshootfor.

Thegapisnotgoodonthefrontleftfenderandthehood,evenwiththefactoryfenderandhood.Thisfenderlookslikeithashadsomebodyworkdonetoitinthepast.

Whenyougetreproductiontrimpieces,theydon’talwaysfitthesheetmetalperfectly.Youalwayswanttopre-fitthosebeforeyoupaintthecarsoyoudon’tfindouttheydon’tfitafterwards.Thisisverycommononthelongerpiecesoftrim.Thehoodmoldingonthis

cardidn’tfit,soasecondonewasordered.

Thegapbetweenthefrontedgeofthisrockerpanelandthefrontfenderwasbad.Wetookacut-offsawandmadeasliceabout1/16-inchthick,andwiththatslice,wecould

condensetherockerormakeitwider.Wecutthefrontoftherockerwithacutofftoolandbroughtitalittlefartherforwardtomakeitfitbetter.It’sfilledinwithweldandground

smooth.

Ontherockerandrearquarterpanel,ahorizontalcutwasmadeandfilledwithweldtomakethedoorgapbetter.Wealsocutaroundthecornertomaketheradiusofthedoor

openingfittheradiusofthedoor.

Hereistheotherrockerpanelonthedriver’sside.Ahorizontalcutwasmadeandfilledwithweldtomakethedoorgapbetter.

Thisismuchbettergaponthebottomofthedoor.

Invariably,frontfendershavesomesortofdraintowardthebackofthefenderwithaholeinthebottom.It’snotuncommonevenforwesternvehiclestohavedirtorleavesgetin

thereandplugthehole.Waterwillthengetinthereanditwillrustout.

Herewe’llmakeourownrepairpanelbecausewe’vegotanEnglishwheelandplanishinghammers.Wedidn’tneedtobuyapanelorpatchpanel.Alwaysuseweld-throughprimeronanyareasthatyou’regoingtocoverupwitharepairpanel.Theinnerstructureofthe

frontfenderisprimedbeforeweputthecustom-madepatchonit.

Thepatchisprimedonthebackwithweld-throughprimerandthenweldedin.

Thefloorpansonbothsideswillbereplaced.Thereplacementfloorpanisbiggerthanneeded,soitwillbecuttofit.Maskingtapeisusedtomarkwherewewanttocutboththe

oldpanandthenewone.

Theoldfloorpaniscutwithaplasmacutterorcut-offsaw.

Thefactorybraceundertheoldfloorpanissavedandre-usedonthereplacementfloorpan,whichdoesnotcomewiththatbrace.Thebraceispaintedwithweld-throughprimer.

JoshWiserweldsinthenewfloorpanonthepassengerside.

Theprocesswillberepeatedonthedriver’sside.

1962IMPALASSREVIVAL:PRIMER

Finalbodyworkandgettingreadyforprimetime

StoryandphotosbyBrianEarnestDependingonhowyoulookatit,whenyougettothefinalbodyworkstageofacollectorcarrestoration,thehardpartiseitherover,orit’sjustbeginning.Bythistime,alltheoldpainthaslongsincebeenremoved,anyrustissuesshouldhavebeenaddressed,dingsanddentshammeredout,andanyotherbigproblemsareasaddressed.Allthat’sleftistogeteverysurfaceonthecarperfectlystraight,sandedand

readyforpaintandprimer.Ofcourse,thatsoundsaloteasierthanitis,especiallyifyourendgameisashowcarfinishthatwillimpressnotonlyallyourbuddies,butsomefinickyjudgesatacarshow.

JoshWiserrunsa“MudHog”8-inchsanderoverthedecklidofthis1962ImpalaSSinoneofthefinalstepsbeforethecarwillheadtothepaintboothforitsfirstcoatofprimer.

Awidevarietyofsandingblocksareusedduringthebodyworkprocess.Longboardslikethiscomeinhandywhenallthedentrepairsandstraighteninghavealreadybeendone.At

thisstage,it’sallaboutgettingtheflattest,smoothestsurfacepossible.

Do-it-yourselfersmightnevergetasgoodatfinalbodyworkasaprofessionalcrew,liketheoneatKen’sKlassicsinMuscoda,Wis.,butiftheyavoidmakinganybigmistakesandtaketheirtime,theycangetclose.Ahandfulofusefultoolsandmaterials,abunchofpatience,andsomeseriousattentiontodetailarerequired.Itdoesn’thurttostartwithadecentvehicletoworkon,either.“I’dsayoneofthebiggestmistakesisnotstartingwithagoodbaseatthe

beginning,”saidT.J.Krueger,theshopforemanatKen’sKlassics.“Theygetinahurry…Wegetcarsinallthetimeandwejustsay,‘Wow,Ican’tbelievetheydidthat.’PeoplewilltakeBondo-Oandspreaditovershinypaint.Oroverrust.Youreallyhavetostartwithagoodbaseandworkyourwayup.Youwantto

startwithmetalthat’sascleanasyoucangetit.It’sgottaberoughedupforsure,becausethatfillerhastoadheretosomething.Alotoftimeswhenyouseepaintthatthat’scracked,it’sjustnotpreppedright.Evenifyouarejustpaintingacarathomeorfixingadent,andmaybenotstrippingacar,youneedtoprepitright.Getthedentout,getitgroundproperlyandprimearoundit—allthewayaroundtheworkarea.”

Thedevilisinthelittledetailswhenitcomestofinalbodywork.Everylittlecreaseandholearoundthedoors,trunkanddecklidmustbeaddressed.Therearen’talotoftools

involved—justsandpaper,sorefingersandpatience.Here,Wiserworksonafewlast-minutetouchesaroundtheImpala’sdriver’ssidedooranddoorjamb.“Fitandfinishisabig,importantthingonthesecarstothesepeople,”saidKen’sKlassicsshopforemanT.J.Krueger.“Everylittlenookandcrannyofit,allthewayintothejambsandeverything.

Everythinghastobenice.”

BeforetheImpalaisrolledintothepaintbooth,Kruegergivesitafinalgoing-overwithhisbarehands.“Iusuallyrunmyhandsovereverythingonefinaltimewhenwe’realldone

withit,justtocheckitonemoretime,”hesays.“Sometimesyou’llfindlittlestuffwithyourfingersthatyoucouldn’tseewithyoureyes.”

“Asfarasgettingthingsstraight,forusthat’sjustguyswithtalentwhohavealotofyearsdoingit.There’snotalotofguyswhocanjustcomeinandyoucanteachtheminacoupleweekshowtomakesomethingniceandstraight.That’sjusttalentandexperience.”TheKen’sKlassicscrewfollowedtheirstandardprotocolwhenitcameto

finalbodyworkona1962ChevroletImpalaSShardtopthatwasintheshopforacompletelyrestoration.Afterthecarwascompletedisassembledandsodablasted—somepartswerechemicallystripped—thecrewgotbusydoingallthedentandrustrepair.Fromthere,theyfollowedtheirusualseriesofsteps.“Whenthecarfirstcomesbackfromthesandblaster,usuallywe’rerunan80-

gritoverthecarjusttoknockallthehighpointsdownfromallthesodablastingandsandblasting,”Kruegersaid.“Usually,theysodablasttheexterior,sothat’salotsmootherthanthejambsandanyofthe[inside].Thenwe’llputRusticideonit.Youspraythatonandrubitinwithascuffpadandwipeofftheexcess.That’slikea320-gritscuffpad,andthatgetsdowninallthelittlerustpitsoranythingthesodablasterdidn’tget.”

Boththebodyshellandthepanelsthathavebeenremovedwillbehitwiththreecoatsofprimer.Ken’sKlassicsusesRustDefenderfromZ-Chromeasitsmainprimer.Theprimerdriesfast.Iffreshlyprimedpartsareputundertheshop’sbakelamp,theycanbesanded

thenextday.

TheRusticideisappliedimmediatelyandkeepsthebaremetalfromoxidizing.Therustinhibitorwilleventuallyberemovedwith180-gritpaper.“We’lltrytohitanywherethat’sbeenweldedwith24-gritonagrinder.Then

we’llDuraglasthat.Duraglasisalotstronger.Anywherethattherewasadeeperdentoranything,andyou’vehammeredanddollieditoutasgoodasyoucangetit,you’llDuraglasoverthoseareas.Thenyouhitallthatwith36-gritjusttoroughthatoff,thenyougooveranydingsanddentsinthecarwitha36-gritonthegrinder.

“Thenyouputyourcoatoffilleronthosespots.Basicallywhatyou’redoingisgettingallthatroughedout,whereeverythingisflat,andthatwefinishedinabout80.Youcanskimcoateverythingoverthe80grit,andthat’swhenallthelongboardscomeout.”Powerdiscsanderscancomeinhandyforsomeoftheroughfinishingwork,

orsmoothingoverspotsthathavebeenweldedand/oraddressedwithDuraglas.

Frontfenders,doors,hoodandtrunkareallhungandprimedseparatelyfromthebodyshell.Thesefenderswillbeshotwithprimeratthesametimeasthehood.Thebodywillbe

primedandpaintedlast.

Alotoftheworkinvolved,ofcourse,isgoodold-fashionedelbowgreasewithfoldedsandpaperorsmallsandingblocks.“Youdon’twanttostandtherealldayandsandofffillerbyhandwhenyoucouldbeusingapowertool.Weallhaveatimelimitonwhenweneedtogetthingsdone,andwehavedeadlinestoo,”Kruegeradded.“Butalotofitisjustgoingaroundeveryinchofthecarbyhandandgettingeverylittlenookandcranny.

Thepanelsaregiventhreecoatsofprimer,thensprayedwithalightguidecoat.“Thatguidecoatwillshowusanyspotsthatneedattention,”notedToddSletten,whois

sprayinghere.“It’sjustablackcolorweputonitandwhenwegetsandedwithourlongboards,you’llseeanylittlepitoranywavesoranylittleimperfections.You’llknowwhat’s

goingon.Everyhtingweputprimeron,weputaguidecoatonit.”

PINSTRIPINGFORMEREMORTALS

Youdon’thavetobeaprotoearnyourownstripes

ByGeraldPerschbacherYoucanaccentyourfavoritevintagecarwithnewpinstripes,andallittakesisalittlepreparation,someresearch,afewtools,somespecialtape,andtime.Allpinstripeswereputonthefeaturedvintageluxurycarinlessthaneighthours!Itmaytakeevenlesstimeifyouarestripinga1970sor1980scarusingthesetips,too.

Step1—Acollectorcar,regardlessofvintage,oftenneedsanextratouchofpinstripingtocapoffarestorationandgivethecarastrikingappearance.Thiscar,vintage1925,hadbeenpinstripedbybrushabout30yearsago,butnotverywell.Beforenewstripeswere

added,theareaswerecleanedofdirtandpolish.

Step2—Paintingpinstripestakesgreatcareandseldomturnsoutrightthefirsttime.Manypeopleusepinstripingtapeinstead.It’simportanttobuyagoodgradeofqualitytape.Itcanbeorderedinrollsof150feetorless;checkwithanautoaccessoriesstore.

Selectthecoloryouneed,andmeasuretheareastoestimatethelengthrequired.

Step3—Sometimesacarcallsforasinglestripe,butthetapecomesinparallelstripesofdifferingwidths.Simplycuttheclearadhesivesectiontoseparateonefromtheother.

Keepyourhandscleanatalltimeswhenworkingthetape,andavoidkinksorpullsthatwillstretchit.Savewhatyoudon’tneedbyrollingitback.

Step4—Asteadyhand,warmtemperature,dryconditions,goodnaturallight,nowind,nodistractions,andagoodeyeforastraightlineareimportantqualities.It’sbestnottotalkwhenworking.Peelthebacking,pressthetapeinplace,thenpeeloffitstoplayer.Ifthe

lineneedstobere-stretched,dosobeforeitisrubbedfirmlyonthesurfaceandbeforethetoplayerisremoved.

Step5—Whenworkinganedgebetweenbodyanddoor,youcanwrapaboutaquarterinchoftapearoundthepanel.SlicewithanX-actoknife,andpressflatwithasteadyhand.Thetapeshouldberubbedinfinalpositionwithaclean,softcloth.Itmaytake72hoursin

sunlightandwarmtemperaturesforthetapetobindwiththesurface.

Step6—Hereisanareaaroundexteriordoorhandlesthatbeggedtoberestriped.Theoldpaintedstripingisfaintandwasunevenlyapplied.Thecolorwaslemonyellowtomatch

otheraccentsonthecar.Thesamecolorwasavailableinpinstripingtapeonspecialorder.

Step7—Thesameareaisshownafterapplyingthetape.Theheavierlinewasadded.Beforedoingtheworkandorderingthetape,checkreferencestoverifythelocationandwidthofpinstripes.OnClassiccars,thisoftenwasoptionaltothewhimofthebuyer.

Step8—Don’tgowildwithpinstriping,butuseitsparinglyandwhereappropriate.Manyvintagecarswithlouveredhoodscarriedstripesinvariouslocations.Checkwithfactory

literature,ownersofsimilarcars,andexpertsinthehobbyifyouhavequestions.

Step9—Whenfinished,youcouldbeamazedattheresults.Thiscartookonaneatnessitneverhadsincenewandwasmadetolooksporty,eventhoughitisasedan.Pinstripingaccentuatesthelinesandcurvesofthebody.Nowyou’rereadyforthenextshow!Seeif

anyonenoticesthechange.

SECTIONTWO

INTERIOR

CUTTINGARUGMakingautomotivecarpetonabudget

StoryandphotosbyJimThorpeTheflooringinmy1939Buickwasbadlywornandtorn.Ihadfloormatsovertheoriginalrubberfloorcovering,butwhatIdidn’thavewastheseveralhundreddollarstohaveaprofessionalshopmakenewfloorcovering.AsolutioncametomeasIwatchedinstallersreplacethecarpetinmyneighbor’shouse.

Theoriginalrubberfloormatisdeterioratinginthis1939Buick.Sincereplicatingtheegeandribbingoftheoriginalmatwouldbecost-prohibitive,theownerchosetocarpetthe

floorofthepassengercompartment.

Threemenpulleduptothehouseearlyinthemorningandsoonbeganrippingoutmyneighbor’soldcarpetandpad.Itwastakenoutside,bundledandthrown

ontotheirtruck.Thenthethreeofthemsweptthedrivewaycleanofalldebrisandunrolledthe

newcarpetface-downonthedriveway.Theymeasuredofflargepiecesandtookthemintothehouse.Upuntilthispoint,theyhadn’tacknowledgedme,butaroundnoon,Idroveovertoalocalhamburgerstandandbroughtbackabagofburgersandfriesforthem.Theyinstantlybecamefriendlierandbegantalkingtomeaboutwhattheyweredoing.ImentionedthatIhadanantiquecarwhichneedednewflooringandaskedif

theycouldgivemeafewhints.Intheend,theygavemealotofveryworthwhileinformation:*Considercarpetinsteadofrubbersheeting.Theoriginalrubberwas

probablymoldedtofitcurvesandbends,andthattheoriginalrubberprobablyhadanedgemoldedintoit.Buyingrubberbytheyardatthelocalhomebuildingstorewouldprobablynotproperlylayorfitlikecarpet.

Plushorvelvet-facecarpetingissuggestedforanautomotiveortruckapplication.

*Cleanthedrivewayorthegaragefloortocreatealargeworkspace.Makenotesandtakemeasurementswheretheoldcarpet/floorcoveringdidnotfitwell,

orwasrippedortorn.Patchthetornfloorcoveringusingbrownpaperandducttape.Thiswasprobablythemostimportantstep,becausewithoutagoodpattern,newflooringjustwon’tfit.

PopularCarpetTexturesandWeaves

BERBER-atight-knottedloopfiber.

INDOOR-OUTDOOR-averylow,tightloop.

PLUSHorVELVET-asoft,smooth,evenfacetexture.

PATTERNEDPLUSH-acombinationofalowloopandplushgivingapatternedlook.

SHAG-alongfiberthatoffersacasuallook.

*Properlyorientatethecarpet,andaboveall,keeptheknifebladesharp.ThatbecameevidentasIwatchedthemwork.Theyregularlybrokeoffthewornblade,replacingitwithanewsharpedge.*Donotconsiderindoor-outdoorcarpet.Useaverygoodqualityplushor

velvet-facecarpeting,butnotashagorwhatthecarpetinstallerscalledaBerber.(ABerbercarpethasaloopweaveratherthanaplushcarpet.)Carpetcomesin12-foot-widerolls,andtheinstallerssaidIwouldprobablynotneedmorethanonelinearyardtocarpetanentirecar.Theysuggestedobtainingcarpetfromanoutletsellingdiscontinuedor“shortrolls”atdiscountedprices.Theinstallerssaidevencarpetstoresandhomebuildingcentersofferaverygoodqualitycarpetforabout$12-15asquareyard(3feetby3feet,soonelinearyardof12-foot-widecarpetis4squareyards).

*Thecarpetinstallerssuggestedanyloncarpetratherthanapolypropylene,althoughpolypropyleneisvirtuallybullet-proofandcanbecleanedwithalmostanycleaningmaterial.Mostcarsfromthe1920sand’30susedwoolorcottonblendsofcarpeting.Syntheticswereverynewandinlimiteduseatthattime.Today’snylonisbetterthanthewoolorblendedcarpetsof80yearsago.

Useanewknifeandfrequentlyreplacethebladessotheyarealwayssharpwhencuttingthecarpet.

*Buyasolidcolorwithasmoothplush/velvetfaceinsteadofapattern.Matchingapatterninacarcanbeverydifficult.*Theedgeofcarpetwillfray,causingloosethreadsaroundeverycutinthe

carpet.Bindingthecarpetwouldbeveryexpensive;itisdonebyonlyafewplacesthatchargebythelinearinch.Ifiguredoutareallycheapalternativethatseemstobeworkingwell.Thatbagofhamburgerspaidtremendousdividendstomeininformation.

MakingCarpetDucttapewasusedtorepairandpatchmycar’soriginalfloorcoveringsothat

Iwouldhaveaone-piecepattern.Thetaped-upfloorcoveringwascarefullyliftedoutofthecar.Undertherubberwasapaddingmadeofabrownmaterial.Itwasfallingapartandleftalotofdustbehind.Itriedtoremoveitinonepiece,butwithouttoomuchsuccess.Betweentherubberandthepadding,Ihadenoughtoprovideagoodpatternforthenewcarpet.Thefrontandrearseatbottomwereremovedtoprovidemoreworkingroom.

Italsoallowedmetofitthecarpetundertheseat.

Imeasuredthefrontandrearfloorcoveringandfoundthatneitherexceeded36inches,sooneyardofcarpetwouldbeenough,evenprovidingalittleexcess.Thatexcessallowedmetocutthecarpet1inchlargerthanthepatterntomakesurethateverythingfitwell.Oneyardofwall-to-wallcarpetingwaspurchasedatalocalcarpetstorefor

about$8persquareyard.Thestorehadrollsofcarpetandwaswillingtoselljustoneyard.ItalsosuppliedmewithsamplecardsthatIcouldtakehometoselectthebestcolor.Insteadofsellingmenewcarpetpadding,thestoresuggestedthatIcutoffapieceofusedpaddingfromajobthattheyjustcompleted.Theytoldmetolookforlarge,undamagedsectionandcutwhatIneeded.Theydidn’tchargeme;theysaiditwasgoingintothetrashanyway.

Asampleofthecarpetpadding.

Minwaxpolyurethanewasspreadontheedgesofthecutcarpettopreventitfromfraying.

IdecidedtotrymyluckwiththepaddingbeforeIcutintothecarpet.I’mgladIdid.Iimmediatelymadeamistakethatmyfriends,thecarpetinstallers,warnedmeabout:orientation.Ilaidthepaddingfaceupinthedriveway,andthenIlaidmypatternontopofit—facedown.ItracedthepatternwithaSharpiemarker,andusinganewknifeblade,cutoutthepattern.WhenItrieditinthecar,IdiscoveredthatitwasamirrorimageofwhatIneeded.Mymistakewasnotplacingthepatternfaceupontheface-uppadding.

Fortunately,IhadplentyofextrapaddingandIdidn’twastetheexpensivecarpet.

Itracedtheoutlineofthepatternonthepadding,andthentracedthecut-outsfortheclutch,brake,gas,dimmerswitchandsteeringcolumn.Ihadsavedsomelargecartonsandusedthemunderthepadding,andlaterunderthecarpet,sothattheknifebladewouldnotrubagainsttheconcretedriveway.IcarefullycutthepaddingalongtheSharpiemarks.Ithencutouttheopeningsfortheclutch,brake,etc.IcutastraightlinefromeachoftheholestotheupperedgesothatIcouldfitthepaddingovertheclutch,brakeandgaspedalsandsteeringcolumn.WhenIwassatisfiedwiththefitofthepadding,Iwentontothecarpetitself.

Thecarpetshouldbecutonthebacksideandneverontheface.Iwasalsotold

thatmycutsshouldbedeepenoughtocutallofthewaythroughthejuteorrubberizedbacking,butnotdeepenoughtocutthepile.Thattookpractice.Withthepatternlaidoutonthebackofthecarpet,ItraceditwiththeSharpie,

butIgavetheoveralloutlineoneinchextratoallowforerrors.ThenItracedtheexactsizeoutline,soIactuallyhadtwolineslaidoutonthecarpetbacking.ThefirstthingIdidwasputanewbladeintheknife,thenIcutalongtheouterlinewithasmooth,evencut,notwithasawingmotion.Ithencutouttheopeningsforthegas,brakeandclutchpedalsandthesteeringcolumnandcutaseamtoallowthemtobefittedovertheshafts.Ilaidthenewcarpetoverthepaddingandfoundthattheone-inchextrawas

needed.Thepaddingisthickerthantheoriginal,soIhadtotrimthepaddingsothatitwouldn’tpeekoutfromunderthecarpet.Onthebackofthecarpet,Imarkedwherethecarpetwastoobig.Iremovedthecarpetandlaiditout,facedown,onthecardboard.Withafreshblade,Itrimmedthecarpetaccordingtothenewmarks.Thisstepwascompletedseveraltimestogetareallygoodfit.Thefloorlookedgreatandfeltterrificwiththenewpaddingunderneath.

Availableinmanytrailersupplyormotorhomestores,snapsonatapestripareconvenient.

Velcrotwo-sidedtapehasonesidetinyhooksandtheothertinyloops.

Myfinalstepwastopreventtheunravelingoftheedgesofthecarpet,whichwasalreadybeginning.Iagainremovedthecarpetandverycarefullytrimmedanyloosethreadsfromtheedgescutbytheknife.Water-based,clearMinwaxOil-ModifiedPolyurethane,awater-basedpolyurethanethatcanbecleanedupwithsoapandwater,wasthenliberallyspreadonthebacksideofallthecutedges,beingcarefulnottolettheliquidgetontothefaceofthecarpet.Afterlettingthepolyurethanedryforacoupleofhours,Igaveitasecondcoat,thenathird.Thefirstcoatsoakedintothecarpetedges,andwhenitdried,providedatoughedgetopreventthecarpetfromunraveling.

Theeyeletisinstalledinthecarpet,andawoodscrew(orbolt)fittedthroughafinishingwashergivesaclean,finishedlook.

Theknifeandaverysharppairofscissorswereusedtotrimmissedthreads,andthenItouchedupthosespotswithmorepolyurethane.Iletitdryovernight,andthenextdayinstalledthenewcarpetandreinstalledtheseats.Itlookedverygood,althoughnotasgoodasprofessionallyinstalledcarpet.

However,itcostmealotlessandthequalityofthecarpetwasmuchbetterthanwhatIhaveseeninmostcars.

JimThorpeownsa1939Buickthathasbeeninhisfamilysincenew.Formanyyears,itlanguished,unlovedandforgotteninagarage.Jimhasgotitrunningandisslowlyrestoringthecar.

ThisarticleoriginallyappearedintheApril2013issueofSkinnedKnuckles,amagazinededicatedtotheauthenticrestorationofcarsandtrucksandtothepreservationofvehiclesfromthebrasserathroughtheearly1970s.Itis

availablebysubscription.Articlesarecopyrightedandallrightsreserved.Reprintingauthorizedbywrittenpermissionofthepublisheronly.BeginasubscriptionbycontactingSkinnedKnuckles.(Seeadonpage21ofthisissueofOldCarsGuidetoAutoRestorationforaspecialsubscriptionoffer.)SkinnedKnucklesmaybereachedatphone714-963-1558,e-mail

sk.publishing@yahoo.comandatwww.skinnedknuckles.net.ItmayalsobereachedbymailatP.O.Box6983,HuntingtonBeach,CA92615.

UPHOLSTERY101AcustomChevrolettruckgetsnewarmrestsusing

fundamentaltemplatemakingandsewingtechniques

ByBrianEarnestChrisArendtofFastFreddie’sRodShopinEauClaire,Wis.,neverpicturedhimselfsewingforaliving.Notinamillionyears.“Ithoughtsewingwasfor

girls,”hejokes.“ThelastthingIsewedwasapillowcaseinjuniorhigh[homeecclass].”Nevertheless,whenhisshopneededsomeonetostepforwardandlearnthe

autoupholsterybusiness,Arendtwentoutandboughtanindustrial-strengthsewingmachineandturnedhisattentionfrommetaltofabric.Inlessthanayear,hehasbecomeFastFreddie’sone-manupholsteryshop,puttingtogethereverythingfromfull-blowncustominteriorstoboatcovers.“Weneededit.Itwastheonethingwecouldn’tkeepinhouse,”saysArendt.

“Youhavetobookacar[withanupholsterer],andyouareattheirmercy.Youhavetoloadit,youhavetotransportit.It’soutofyourcare,typically.Thingscanhappen.Youcangetelbowdents,orpaintchips.Youhatetohavesomethinghappentoit.”Recently,hebeganworkonanewinteriorforacustomer’s1949Chevrolet

custompickup,whichisalmostdone,butneedssomeupholstery.Oneofthefirststepsinthetheprojectistakingapairofnewreplacementarmrestsandrecoveringthemwiththecorrectdarkergrayvinylthatwillmatchtherestofthepickup’sinterior.

Thisarmrestisanewpiecethathasnotbeenonthetruck.Ithasalight-grayvinylcoveringontopandametalbracketforstabilityonthebottom.Thebracketisheldinplacewitha

pairofscrews.

Comparedtosomeofthestart-from-scratchcustominteriorprojectsthatupholsterersoftenface,fabricatingnewarmrestcoversforthistruckisafairlystraightforwardpropositionthatusessomebasictechniquesandtheexistingmaterialasapattern.“We’regoingtoremovethematerial,steamitouttomakeitlayflat,makea

simpletemplate,cutitoutandstitchitbacktogether,”Arendtsaid.“Thiswillbeasimpleproject.Justessentialtemplatemaking.Youbasicallyusethesesimplestepsthroughoutawholeupholsteryjob.It’snicewhenyouhaveanexistingpiecesoyoucanmakeanaccuratetemplate.”Thearmrestwillbeputtogetherusingasimpleflatfelledseem,whichties

togethermultiplelayersoffabricwithastrongbondwhileleavingtwovisiblestitchlines.AlongwiththefancierFrenchseem,theflatfelledseemisoneofthebasicstitchingtechniquesusedbyupholsterers.Followingisastep-by-steplookatthetechniquesandtoolsArendtusedfor

thisarmrestupholsteryproject.

Thevinylisheldinplacewithapairofstaplesoneachendofthearmrest.Thesearepulledwithastaplepuller.Glueisusedeverywhereelseonthevinyltokeepitinplace.

Ahand-heldsteamingmachinesimilartoanironisusedtoflattenouttheoldvinyl.“Giveitalittleheatandalittlesteam,anditwillflattenitselfrightout…andthatmakesthe

templatemakingjobmucheasier,”Arendtnoted.

Allstitchesarecutandpulledout,resultinginfourseparatepiecesofvinyl.Thesefourpieceswillbelaidoutandusedasatemplatefornewarmrestcoverings.

Whenallthestitchesarecutandpulled,thefourpiecesofvinylarelabeledwithwitnessmarkstoshowhowtheyoriginallywenttogether.

Thepiecesoforiginalvinylfromthearmrestsaretracedontotemplatepaperandthemcutoutwithapizzacutter-typetoolandasingle-edgerazorblade.Thesetemplatesarethen

transferredtothenewmaterialandcutout,leavingfourpiecestheexactsizeandshapeoftheoldpieces.

Theflatfelledseemstartswithtwopiecesoffabricmatchedface-to-face.Whenthefirststitchlineisdone,theseemallowanceisfoldedovertoonesideandasecondstitchlineismade.“IgoasslowasIcanmakethemachinego,”Arendtsays.“IwanttogoasslowasIcan...Youstartthemface-to-face,gray-on-gray.Thatholdsittogether.Thenyouflipit

overandthesecondseemflattensitout.”

Usingthesameflatfelledseem,thefourpiecesofvinylarecarefullystitchedtogether.Forthisproject,amatchinggraythreadwasused,butcontrastingthreadcolorsarealso

frequentlyused.

Anolder-style,syphon-feedautomotivepaintgunwithalargertipisusedtospraytheadhesiveonthearmrest.Paperisusedunderneathtokeeptheoversprayoffthework

table.

Asecondlayerofadhesiveisappliedtotheedgesofthevinylusingasmallbrush.“Whenthegluebeginstosetup,itbecomesareallynicecontactcement,”Arendtnotes.

Smallreliefcutsaremadearoundcurvesandcornerstoallowthevinyltobeglueddownflat.Theindividualtabsareeachhelddowninplaceforafewsecondsuntiltheadhesive

bondsenoughtoholdtheminplace.

Staplesaren’talwaysnecessary,butsincetheoriginalarmrestsusedstaplestoholddowntheendflaps,Arendtdoesthesamewithastaplegun.Itisthefinalstepintheprocessthatresultsinanarmrestthatisalmostidenticaltotheoriginal,butinacolorthatwill

matchtherestofthe‘49Chevytruck’sinterior.

SECTIONTHREE

MECHANICAL

THEHUBOFMOTIONReplacingbearingsonafull-floatinghubsystem

ThisdustshieldshouldhavebeenthefirstpartinstalledwhenbuildingtheDaimler’sfull-floatinghubassembly.Thiswasalate-productionitemnotmentionedintheSP250factory

workshopmanual.

Wemarkedtheoldracesjusttobesurewhichsidewentinfirst.Behindtheoldbearingsandracesarethenewparts.Behindthemarethehubswithknock-offspinners(oneleft-

oneright-hand)onthesmallerouterends).

ByJohnGunnellWehaddoneeverythingoutlinedintheshopmanualtorestorethewirewheelhubsandthediscbrakesonthefrontofaDaimlerSP250roadster.SincetheBritishsportscarhadoriginallybeentakenapartbysomeoneelseandwedidn’thavephotos,drawingsornotesaboutthedisassembly,wethoughtwedidaprettygoodjobputtingitbacktogether.Whywasthereanextrapartleftover?Toanswerthisquestion,wee-mailedDaimlerexpertLaurenceJonesin

England.Bythenextdaywehadananswer.“Theextrapartisadustshieldaddedtolate-productioncars,”Joneswrote.“Itmountsontheinnerflangeofthestubaxle,upagainsttheverticallink(pivotpintoAmericans)andbetweenthelinkandthedustcoverontheendoftheinnerbearing.“ThisaddeddustshieldwasneverpicturedormentionedintheDaimlershopmanual.SincesofewSP250sweremade,theshopmanualwasneverupdated.Jonessaidweshouldusethedustshield,sothatmeantdisassemblingthehubagain.

The50mmcollarfromtheinexpensivebearingandsealdriversetwasflattenedonoppositeedgessowecouldpushitdownpasttheold,largerbearingrace.Then,we

leveleditinsidethehubandusedittodriveouttherace.

AlthoughSP250sarerare,theirunderpinningsareadirectliftfromthemass-producedTriumphTR3andTR3Asportscars.Theyalsohavemanysimilaritieswithothercars(evendomestic)thatusedwirewheelswithfull-floatinghubs.Withfull-floatinghubs,thewheelsaremountedtothehubs.Thiscontrastswithsemi-floatinghubswherethewheelsaremountedtotheaxles.Withfull-floatinghubs,thehubs(nottheaxles)beartheweightofthevehicle.There’sasmalllikelihoodyou’lleverworkonaDaimlerSP250,sinceonly

2,500werebuilt,butsomeofthefollowinginformationandpartssourceswillbehelpfulwhetheryou’reworkingonaBritishsportscaroraModelAFord.Removingandinstallingbearings,greasinghubs,brakerepairsandtipsontoolsareprettymuchuniversal,nomatterwhatvehicleyou’rerestoring.

Often,ahammerormalletpoundingagainsttheproper-sizealuminumcollarfromabearingdriversetwilldoaverygoodjobofinstallingabearingorrace.“Tap,tap,tap”-

typehammerblowswillevenly“walk”araceintoplace.

OntheSP250,thehubsareboltedtothebrakediscs(rotors)withfourbolts.Thehubshaveasmallbearingandbearingraceattheouterendandalargebearingandbearingraceattheinnerend.Adonut-typefeltoilsealfitsintothemetalringthatistappedintotheouterendofthehubafterinstallingthebearingandrace.The“leftover”dustshieldgoesagainstthering.Ithasaflat,angledbottomlipthathooksintotheverticallinktokeeptheshieldfromturning.

Ifyouareusingabottlejackpresstoinstallbearingsorraces,don’tapplysomuchpressurethatthehubcastingfractures—arealproblem.Instead,applypressure,then

backoffandcheckthatthebearingorraceisgoinginstraightandeven.

Theinnerendofthehubpassesthroughthenewbrakerotorandboltsinplace.Greaseisaddedtofillthevoidbetweeninnerandouterbearings.Then,thefeltsealisplacedinthe

dustcover,whichistappedintotheouterendofthehub.

Afterinstallingthesmallerbearingandraceattheouterendofthehub,slidethehub/discontothestubaxle.Thismayknockthesmallouterbearingloose.Ifso,justputitbackinthehubbyhand.Whenproperlypositioned,thelargeinnerendofthehubisagainsttheonce-forgottendustshield.Atthesmaller,outerendofthehub,awasherwithaD-shapedholegoesover

theD-shapedaxle.Pushthewasheragainstthebearingwiththecastlenut,adjustthetightnessofthecastlenutandpositionitsoacotterpincanbeinstalledtokeepthecastlenutfromcomingoff.Thewasherisafinger’slengthinwardfromthehub’souteredge,sothehubhasholesthroughwhichtoinstallthecotterpin.Beforeinstallingthehubontheaxle,positionashield(brakebackingplate)

overthefrontsuspensionmembers.Thiswillbeheldinitsfinalpositionbythesameboltsthatarelaterusedtoattachthebrakecaliper,butfornow,leaveitloose.Next,makecertainthatthepadsinthecaliperarepushedbackandplacethecaliperoverthediscontherearupperpartofthedisc.Theboltsthatattachthecaliperarethreadedattheendsonly,sotheyneedtobetappedabittomakethingstighten.Then,puttheboltsthroughthe“backingplate”mountingbracketsandthecalipers,aswellastheshimsmentionedbelow.

Onthissecondtry,wemadesureweputthedustshieldontheinnerflangeagainstthepivotpin.Theflatbottomhasalipthatfitsintoanopeningonthepivotpinsothedust

shielddoesn’tturnwhenthehubassemblyisinplace.

Factoryshimswereusedunderthecaliperboltstomakeslightinward/outwardadjustmentsofthecaliperontherotor.Thegoalwastomatchtheverticalcenterlineofthecalipertothecenterofthebrakedisc’sedge.Thethinshimsareshapedlikeabarbellwithholesineachendthatthecaliperboltspassthrough.Whendisassemblingacar,carefullynotehowmanyshimsareusedineachside.Sincewedidnothavethatinformationforthiscar,weplayedarounduntilthecenterswerealigned.Thecastlenutadjustmentmentionedearlieriswhatactuallymovesthecaliper

inoroutontherotortogetitoncenter.Theshopmanualstatesthenutshouldbetighteneduntilthebrakediscjustaboutstopsturning.Then,itsaystobackoffthenutfromonetotwoflats(toaspotwherethecotterpinwillslidethoughaholeintheaxleend).Ifthecorrectnumberofshimswereused,thecenterlinesofthecalipersanddiscsshouldbeclose.

Naturally,thehubshavetobegreased,andtherearenoZerkfittingsorprovisionsforaddinggreaseafterthehubandbrakeassembliesarebuilt.TheDaimler’sshopmanualsaystofilltheentirehubbetweentheinnerandouterbearingswiththepropertypeofgrease.Theinnerandouterwheelhubbearingsthemselves(taperedrollerbearingsonthiscar)shouldalsobeliberallygreased.Theproperfeltgreasesealsweredifficulttofind.ThinkingtheDaimlerand

Triumphsealswereidentical,weorderedTriumphsealsfromMossMotors(www.mossmotors.com)andfoundtheyweresmaller.WefoundthecorrectsealsfromJohnCareyinMassachusetts(www.daimler-sp250.com),whosaidthattheyhadbeen“unobtanium”forawhile,butwererecentlyreproduced.

Withallbearings,feltseals,dustcoversandshieldsinplace,thehubandrotorassemblycanbeslidontothestubaxle.Thismaypushthesmallbearingout,butitcanbepushed

backin.Thearrowpointstothecotterpininstallhole.

AlargewasherwithaD-shapedholefitsoverthestubaxle.Useapieceofpipeandsmallhammertotapthewasherinagainstthesmallbearing’souterretainer.Youmusthavethe

stubaxlethreadshowingtoinstallthecastlenut.

Usingyourfingeroramagnettool,twistthecastlenutontotheendofthestubaxle.Notehowthehubissplinedtomatchupwiththewirewheels.Whenyourinstallisalldone,the

knock-offspinnerwillthreadontotheendofthehub.

Withthechassissupported(hereonaBackyardBuddyEasy-Accessunit),youcantightenthecastlenutuntilthebrakerotorjuststopsturning.Then,youbackoffonetotwoflats

untilyoucandropthecotterpinintotheholeintheaxle.

AstainlesssleevedcaliperrebuiltbyBrake&EquipmentWarehousemountstotwoholesinfrontsuspensionmember.Thecalipermountingboltsarealsousedtoholdthe“backing

plate”thearrowispointingto,plusrequiredshims.

Everypartonthehubassemblywasremovedfromthecar,cleanedorsandblastedandrepaintedwithSatinBlackchassispaintfromEastwood(www.eastwood.com).Thecaliperswerecompletelyrebuiltandupgradedwithstainless-steelinsertsbyBrake&EquipmentWarehouseinMinneapolis(www.brakeplace.com).Wefeelthisistheonlywaytogoinpreventingrustybrakesonacollectorcarthatwillbestored.

Sincewehadthecarcompletelyapartduringitschassisrestoration,wereplacedallofthebearingsandracesinthehubs.Thesmallbearingsandraceswereacommonnumberusedontrailersandwereavailableatanyautopartsstore.ThelargerbearingswerehardertofindandcamefromJohnCarey.Wealsosourcednewbrakediscs(rotors)fromCarey’sNewEnglandAutomotiveRestorations.Thediscswereslightlydifferentthantheoriginals,whichhadslottededges.Wediscoveredwhythenewrotorsweredifferent—manyoftheslotsontheoriginalshadfractured.Drivingoutthesmallerracesthatwereinthehubwaseasy.Theysatup

againstaridgeontheboreofthehubthathadnotchesoneitherside.Weplacedalongpunchwheretheslotswerelocatedandtappedwithahammerandthesmallbearingracesflewout.Itwasadifferentstorywiththelargerinnerraces.Togeteachofthelargeinnerracesout,wetookaninexpensiveBearingRace

andSealDriverSetfromHarborFreight(www.harborfreight.com/10-piece-bearing-race-and-seal-driver-set-95853.html)andgroundtheoppositeedgesofthepurple50-mmaluminumcollarflat.Thisallowedthecollartoslipdownintothehub,pasttheoldrace.Then,wetappedthecollaruntilitwassittingflatinsidethehub,againsttheoldrace,andinstalledthedrivehandle.Next,weputpressureonthedriverhandlewithour20-tonbottlejackpress.Sinceweknewitishardtopressanythinginoroutthatisn’tperfectlyflator

level,weavoidedgeneratinghub-breakingforceswiththepress.Instead,werepeatedlyappliedalittlepressureandsprayedlubricantintothehubtomakepartsslideeasier.Eachtimewestoppedtocheckonourprogress,weadjustedthingssothatwewerepressingstraightandlevel.Eventually,thelargebearingrace,whichhadsatinthehubfor50years,droppedoutwithatelltale“pop.”Flatteningtheedgesofthe50-mmcollardidn’truinitanditstillcamein

handywhenwewerepressinginthenewsmallerbearingrace.Othercollarswereusedtopressinthelargerrace.Sometimes,itseemslikethenewbearingsgoineasierwiththe20-tonpressandsometimestheyseemeasiertoinstallusingrepetitivehammerblows.Again,whenusingapress,thingshavetobeperfectly

straight,whileusingahammertendstomake“automatic”adjustmentswitheachblow.Theimportantthingtocheckisthatthebearingracesseatproperly.Whenthingsareright,thattelltale“pop”or“snap”canbeheardagain.Oneotherthingworthmentioningisthatexpertsinaparticulartypeofcar

oftenusedshorteneddescriptionsforparts.Forinstance,DaimlerexpertJohnCareyreferredtothesmallerhubbearingracesas“1910s,”althoughthefullpartnumberwasLM11910.WhenweaskedtheBumpertoBumpercountermanfora1910bearing,hiscomputeralmostcrashed.Whenwethencheckedtheoldbearingnumberandtoldhimweneededan11910,hefounditontheshelf.

BASICBRAKEBLEEDINGTIPSStoryandphotosbyBobMullerSiliconeisnotmypreferenceforoldervehicleswithhydrovacs.Ifeeltheissuesthesiliconeposesforthesevehiclesoutweighitsbenefits.Thebenefitmostcitedforsiliconeisthatitdoesn’tabsorbwater,soyourbrakesystemwon’tbeexposedtomoisture-basedcorrosion.Theproblemwithglycol-basedbrakefluid(DOT3or4)isthatovertime,itwillabsorbwater.Itisgenerallyaslowprocess,butsinceglycolishydroscopic,itwantstoabsorbanymoisturetowhichitisexposed.Thinkofitasmotoroil:Overtime,itgetscontaminated,andwhileitisstill

working,itcertainlyisn’tprovidingtheprotectionitdoeswhenitisnew.Wetypicallychangetheoilonourvehiclesatleasteverycoupleofyears,butrarelytouchthebrakesystem.Ithinktherearetworeasonsforthis.

Thisisallyouneedforeasybrakefluidmaintenance;notetheadaptedmastercylinderplug,tubing,pressurepump,bleederhoseandcatchjar.

First,“outofsightoutofmind”probablycomesintoplay.Wedon’tthinkofthesystemashavingalotofmovingpartslikeanengine,andifitisworking,whymesswithit?Secondly,itisfranklyapainintheneck.Whileyoucanchangetheoilonsomevehiclesinabout20minutesorso,bleedingthebrakesusuallymeansaprocessinvolvingassistance,lotsoftimeandmorebeerthanyoumaybewillingtobuy.Thisisthereasonmanycarandtruckownersareunderstandablydrawntothelongevityofsiliconebrakefluid.Iwasinthesameboat—Ididn’twanttomesswiththebrakesasitwasjust

toomuchofapaintodealwith.Likealotofthosetypesofthings,itfellunderthecategoryof“Iwilldothatnextyear.”Likeoilchanges,youcancertainlyletitride,butintheprocess,youaregoingtolosesomeprotection.Wouldn’titbegreattobeabletousestandardglycolbrakefluid(DOT3or4)andhavethe

advantagesofeasyaccesstofluid,lowercostandnoriskofpotentiallyharmfulsilicadamagingyourengine?Thedownsideisthatitprovidesallthesepositiveswithoutthenegatives,only

ifitgetspurgedeveryfewyearsbeforemoisturecanbuilduptounacceptablelevels.Iftherewereaneasierwaytodothis,itwouldsolveamultitudeofproblems.

Whenfillingthepressurecanister,pourslowlydownthesidelikefillingabeermug.Thishelpspreventairmixinginwiththefluid.

Thesearchforthe“magicbullet”wason.Ihaveusedthemanual“buddysystem”manytimes.Whileitiseffective,itdependsonhavingabuddywhoseschedulecoincideswithyours,willlistentodirections(thiscanbemorechallengingthanoneimagines),onewhodoesn’tlikeyourbeertoomuch,andonewhowillwaitpatientlywhenyoufindyouneedtoreplacetheoccasional

bleederorhose.AsIsaid,itworksgreat,butrarelyisitaconvenient,efficientwaytobleedyourbrakes.

TRIALANDERRORMyfirstforayintobrake-bleedingsystemswasthepurchaseofafullsetof

“checkvalve”-typebleeders.Thebleedershaveatinycheckvalvebuiltintothemwhichallowsfluidtoexitwhenthatbleederisloosenedandthebrakepedalisdepressedwithoutallowingairtobesuckedbackinwhenitisreleased.Inconcept,thisseemedlikealogicalandsimplesolution.Inmyownexperiencethough,Ihittwosnags.First,itisdesignedasasingle-personoperationwithyoupumpingthebrake

pedal.Unfortunatelysittingbehindthesteeringwheel,youhavenoideawhatishappeningatthebleeder.Istheairout?Didthehosestayon?Howmuchfluidcameout?Ipersonallyliketoknowwhatishappeningwiththesystem.Thesecondissuewaswiththebleedersthemselves.Inordertoincorporatethe

checkvalve,thebleederismadefrommuchmildersteelthanastandardbleeder.Onehastousesealertostopthemfromleaking,andittakesverylittlepressuretoroundthemofforstripthemout.Therealitywasthattheycausedfarmoreproblemsthantheysolved.Mynextstepwastotryavacuum-bleedersystemmadebyMityvac.These

systemswillrunfromabout$50foramanualsystemtoabout$150foronethatrunsoffacompressor.Itriedthemanualversionandwhileitworked,Ifoundafewissuesthatmadeitproblematic.First,thevacuumreceiverthatcollectsthefluidwassmallandtherefore

limitedthefluidthatcouldbedrawnin.Thiswasn’tahugeproblem,asitcouldbedumpedanddrawingfluidcouldresume,butitwasapainnevertheless.Moreofanissuewasthatyouhadtobeverywatchfulofthemastercylinder

fluidlevel.Justwhenyouthinkyouaregettingoutthelastoftheairbubbles,youwilleitherhearorseethemastercylinderempty,andbeginpullingafreshsetofairbubblesintothesystem.Youarenowrightbacktosquareone.I

cautionyouthatsmallchildrenshouldbekeptfromtheshopareaontheseoccasions,asusuallythestringofprofanitythatfollowscouldscarthemforlife.Aftertalkingtosomeprosanddoingmyownresearch,Idecidedtotrya

pressurebleeder.Afteralittletrialanderror,Ican,unequivocally,saythatapressurebleederisbyfartheeasiestandfastestwaytobleedbrakes.Withalittlepreparation,itisaneasy,one-personoperation.

Acatchjarwithawide,stablebaseisfarbetterthantheusualsodabottle.Itwon’ttipoveraseasyandyoucanseewhatishappeningwithoutholdingonthetubingifyouputa

smallholeinthelid.

BLEEDINGYOURBRAKESAnew,universalpowerbleedercanbehadforabout$75.Mostarespecificto

vehiclemodels,butthatdoesn’treallymatterasallyouneedisthepressurecanisteritself.Themaindifferencebetweenthemodelsisjusttheterminalendthatgoestothemastercylinder,andyouwon’tbeusingthatanyway.Whatyouneedisjustthepressurecanister,amodifiedmastercylinderplug,someextra

tubingforthebleeders,afluidcatchtankandfreshbrakefluid.Herearethesteps:1.Getanoldcap/plugthatfitsthemastercylinderandtap,epoxyorsoldera

hosebarbintoit.2.Fillthemastercylinderwithfluid,thenputonthemodifiedcap.Thisisan

importantstep,evenifthereisoldfluidinthecylinder.Iteliminatesthechanceofairgettingintothesystem.3.Iaddedathreadedjointinthehosethatattachestothemodifiedcap.This

makesiteasiertoinstallthecapbeforeitisattachedtothepressuretank.Asmallunionjointwouldbeevenbetter.4.Carefullyaddfluidtothepressuretank(pourslowlydownthesidelike

beerintoamugsoasnottomixinair).Putinenoughsoastonotrunout,andkeepandeyeonthelevel.Ifyouwanttopurgealloftheoldfluidandairfromthemastercylinderthroughtheentiresystem,youwillwantatleastafullquart.5.Tightenthecaponthepressurepumpandpumpituptoaround8-12psi.

Youdon’tneedmuchmorepressurethanthis,andyouwillfinditwillholdthispressureprettywellthroughtheprocess.6.Tocollectthefluid,findaclear,plasticjarwithawidebottom(sothehose

oryoudon’ttipitover)anddrillaholeinthetopforthebleederhose.Keeptheholejustabitsnugonthehosesoitdoesn’tpullouttooeasily.Thisisarealhelpasyouwon’thavetoholditandcanfocusyourattentiononthewheelcylinders/bleedersinstead.7.Startasyounormallywould;attachthebleederhosetothebleedersonthe

hydrovacfirst,thenthewheelcylinderfarthestawayandworkforward.Youwillgetafairlyvigorousstreamoffluidandjustwaituntilitflowsclearofbubblesbeforeclosingthebleederandmovingtothenext.8.Keepaneyeonthefluidinthepressuretanksoitdoesn’trunoutandpush

inair.Thisiseasy,asyoucaneasilyseetheleveloffluidintheopaquepressuretank.9.Whenyouaredone,besuretoreleasethepressureinthetankbeforeyou

disconnectthehoseandcaporyouwillhavequiteamess(the“error”partin“trialanderror”).Ilayafewragsornewspapersdownonthefloorofthecabandwherethepressuretanksitstocatchthedropsoffluidboundtodripduringassembly/disassembly.10.Savetheoldbrakefluidandmixitwithatinybitofacetoneaspenetrating

“rustbuster”fluid.Itypicallydon’ttrytosavepartialcansofbrakefluidunlessIknowIwillbeusingitwithinthenextmonthortwo.ItisprettyinexpensivestuffandIwanttostartwithfreshifIamreplacingthefluid.11.Aftercleaningup,Istorethepressurecan,hoses(inaplasticbag),used

fluidreceptacle,themodifiedmastercylindercap(s),andsparebleederstogetherinaplasticstoragebin.ThisnotonlykeepseverythingIneedtogetherinoneplace,italsokeepsthedustanddirtoftheshopoutofthesystem.Keepingyoursystemfreeofanydustanddebrisshouldbeapriority.12.Glycolbrakefluidwillharmpaintifallowedtositonittoolong.Ifyoudo

spillsomeonpaint,cleanituppromptlywithwaterandabitofdetergent.Youcancompletelychangeyourvehicle’sbrakefluidinlessthan15minutes

aslongasthebleedersareOK.Itisliterallythateasy.Ialsofeelthepressuresystemdoesabetterjobofpurgingtheoldfluidoutasitisastronger,moreconsistentflow.Italsoprovidestheadvantagethatyoucanseewhatishappeninginthepressurecanister,inthetubing,andcanaddfluidasneededwithoutissue.

POWERPACKAGESCrateenginesthatrockoutofthebox

Mopar572Hemihasoptionalcrossramsandairhorns.Withits10.0:1compressionratio,itgenerates560hpand660lb.-ft.oftorque.

byJohnGunnellLikesomanyotherstoday,JeffNollofMilwaukeeinstalledafactorycrateengineduringhiscar’sbuild.Noll’schoiceforhis1967Camarowasthe

ChevroletZZ4H.O.350four-bolt-mainofferedbyGeneralMotors.Theengine’scast-aluminumheadsarefittedwith1.94-in.intakeand1.50-in.exhaustvalvesanda10.0:1compressionratio.Theengineusescast-aluminumpistonswithoffsetpistonpinsonforgedmetalconnectingrods.CrateenginessuchasthatinNoll’sCamaroaregrowingincreasinglypopular

withhobbyiststoday,becausetheycanspeedthecompletionofaproject.Theyalsoprovideawarrantythatprovidespeaceofmindtohobbyiststhatdrivetheircars.InadditiontoGM,FordMotorCo.andChrysleralsooffercrateenginestothehobbyist.

GMFactoryCrateEnginesGMcrateenginescomeinfivefamiliesandnumeroushorsepowerand

displacementcombinations.TheenginefamiliesaretheLSsmall-blockV-8,theChevysmall-blockV-8,theChevybig-blockV-8,RPOenginesandraceengines.The290-hp350H.O.Chevysmall-blockV-8isadealthatdeliversreliability

withitsfour-boltmains,PMsteelrodsandstrongcast-aluminumpistons.FuelinjectionfanscanorderaRamJet350-cid/350-hpGMcrateenginewith

ironVortecheads.Oneofthenicestthingsaboutthispowerplantisthat,onceinstalled,allyouneedisa12-voltpowersupplyandfuel.Youdon’thavetodealwithawholemessofelectricalwires.The383-cidstrokerenginehasbeenbuiltbyroddersforyearsandnowGM

makesitatthefactory.Thiscrateenginepacks425hpandoffersplentyofstump-pullingtorqueat460lb.-ft.GM’s320-hpLS1350providesstate-of-the-artperformanceandfamously

poweredthefourth-generationCamarosandFirebirds.Theall-aluminumsmall-blockV-8comescompletewithfuelinjectors,exhaustmanifoldsandaflexplate.ItalsoincludestheECM(electroniccontrolmodule)andawiringharnessthatallowsittobeinstalledandteamedwithafour-speedautomatictransmissionforuseinany1975-or-earliervehicle.

Hobbyistsfascinatedbythebig-blockmystiquecanordera770-hp,572-cubeGMbig-blockV-8straightfromthefactory.Theoldadagestillringstrue:“There’snoreplacementfordisplacement!”Thebasebig-blockcrateengineisthe454-cid,425-hpmill,whichispricedto

maximize“bangforthebuck.”Thisisagoodclassichigh-performanceV-8withbigvalves,rectangularports,forgedpistons,aforgedcrank,forgedconnectingrodsandfour-boltmains.At500lb.-ft.,ithasplentyoftorque,too.Thenextstepupfrom425hpisGM’sRamJet502crateenginewith

aluminumheads.Thefuel-injected502-horse,565lb.-ft.monsterisjustlikethesmall-blockRamJetV-8—itneedsonlya12-voltgroundtomakeitreadytoride.GM’sZZ572crateV-8isdescribedasbeing“forthosewhoconsiderexcess

tobebarelyenough.”Judgingfromthespecs,there’snoargumenthere.Itpacks620hpfrom572cubicinchesand650lb.-ft.oftorquetoboot,butitcomesatafive-figureprice.

LSX454isaGenIVversionofthe6.2-literChevysmall-blockandissoldinlong-blockform.

ThelastGMbig-blockcrateonthelististheZZ572RaceEngine,whichputsout720hp.Theenginewillcertainlyputadentinyourwalletandisintendedforseriousracers.GMcrateenginescanbefoundatwww.gmpartsdepot.com.

FordFactoryCrateEnginesFordMotorCo.alsooffersfivefamiliesofcrateenginesthroughitsracing

partsdivision(www.fordracingparts.com).Theyarecalled:Modular,Small-

Block302-Based,351-Based,SealedRaceandBig-Block.Thetotalarrayofofferingsincludes20differentengines,someofwhichputoutmorethan700hp.TheModularlineoffers5.0-,5.4-and4.6-literV-8engines.Thenormally

aspirated4.6develops320hpand320lb.-ft.oftorque,whileasuperchargedversioncandeliverupto700hp.The5.0hasa412-hpratingandthatgoesupto550hpforthe5.4.Pricesrangefrom$8,000upto$20,999forthe5.4.TheSmall-Block302seriesoffersfiveenginesincludingthreethatactually

displace302,306and347cubicinches.Allbutthe306areBossV-8s,themostpowerfulofwhichbeingthe450-hp347,whichcomeswithhigh-flowheads,hydrauliclifters,aforgedcrankandanMSDbilletdistributor.Allfiveenginesinthe302familyhavehydraulicrollercams,forgedI-beamconnectingrodsandlightweightforgedpistons.Pricesrangefromlessthan$4,000uptoalmost$9,000.Fordoffersfourenginesinthe351family,twoofwhichdisplace392cubes

andtwoof427cubicinches.The392sarecalledSportsman351s.The427-cid/535-hpengineistheBoss351andtheother427isanaluminum-blockengineforwhichnospecifichorsepowerratingislisted.Theseenginesallhavemanyhigh-performancegoodiesandexternalappearanceupgrades.Pricesareinthe$7,895to$13,595range.Ford’scrateenginelineupincludessixracingenginesthatarespecially

marketedandnotachoiceforresto-mods.Ontheotherhand,bothoftheFordbig-blockcratesarepopularwithresto-modbuilders.Bothhave521cubicinchesandbothproduce609hpat5,750rpm.Bothalsolist630lb.-ft.oftorqueat4,500rpm.Infact,bothhavenearlyidenticalspecssuchasmechanicalrollercams,forgedpistonsand10.0:1compressionratios.

MoParFactoryCrateEnginesChrysler(www.mopar.com)also“imports”threecrateenginesfromDetroit.

Thefirstisanall-aluminum426HEMIGenIII.Ifhorsepowerandspeedcount,thisMoParengine(P/NP5155513)couldbewhatthedoctorordered.With540

hpand530lb.-ft.torque,itapestheclassicHemi.Lightweightaluminumaidsperformancethroughbetteracceleration,braking,vehicledynamicsandweightdistribution.MoPar’s440SuperCommandocrateenginecommandsinstantrespectand

admirationwithanestimatedoutputof500hpand535lb.-ft.oftorque.Withthisengineunderitshood,aresto-modpackspunchonthestreetordragstrip.Last,butnotleast,isthe410Magnum“SixPack”crateenginewith465hp

and500lb.-ft.oftorque.ThisMoParcrateengineispackedwithpowerandadditionalperformancecapabilities.

AftermarketFactoryCrateEnginesInadditiontothecrateenginesavailablefromautomakers,therearemany

aftermarketcompaniesthatmake/sellcrateengines.LingenfelterPerformanceEngineering(www.lingenfelter.com),GaleBanksEngineering(www.bankspower.com),EdelbrockLLC(www.edelbrock.com)andPromarPrecisionEngine(www.promarengine.com)areseveralsources.CatalogsupplierssuchasSummitRacingandSpeedwayMotorsareotherreliablesourcesthatofferguarantees.Purchasingacrateenginefromaless-well-knownsupplierdoesn’tnecessarily

meanyou’llgetrippedoff.Therearecertainlysmallcompanieswhomakeexcellentproducts,sellthemabitcheaperduetoloweroverheadandstandbehindtheirengines.Agreatwaytodealwithanysupplieriscontactothercustomers.Computer-savvybuyerscanalsocheckforInternetfeedbackfromothercustomers.

Crateenginesaren’tjustnewenginesfromthemanufacturer.Thisbuilt-upOldsmobileRocketV-8fromthe1950sisanexampleoftheturn-keyrebuiltenginessomecompanies

offer.

CrateEngineBuyingConsiderationsWhenbuyingacrateengine,realizethatenginepackagescanvaryfromone

companytothenext,aswellasfromonemodeltothenext.Generally,enginesareavailableinoneofthreebasicformats.

Short-block:Thissetupincludestheengineblock,crank,connectingrods,pistonsandpistonrings,pins,mainbearings,rodbearings,cambearings,rearmainsealandwaterjacketplugs.Someincludethecamshaftanddrivemechanism.

This“PoweredByFord”factorycrateenginewasondisplayintheautocompany’sboothattheSEMAShow.

Long-block:Theshort-blockbasicsareincludedpluscylinderheads,camshaft,valvetraincomponentsandoilpan.Usually,thetimingcoverandvalvecoversareincludedand,possibly,theintakemanifold.

Turn-key:Thisisaready-to-bolt-inenginewhichmayormaynotincludeadistributor,beltpulleysorotheraccessories.Buyingthesepartsseparatelywilladdtothecost.Wantairconditioning?Thenlookforthebestdealonacrateenginepackagethatincludesalloftheneededairconditioningsystemparts.

THEPRICEOFPERFECTIONOneman’spassionforrestoringanengineafteritsrebuild

ByJohnGunnellWhenLarryFechtersaidthathecouldspendfourhoursworkingonfuellineclipsforthe’69CamaroZ/28RallySportthathewasrestoringinthewinterof2010,itbecameobviousthathesweatsthedetails.“Idon’twanttoactlikeaknow-it-allbecauseI’mnot,”Fechtersaid.“WhenI

readcarbooks,magazinearticlesandshopmanuals,Istudytheoriginalfeaturesandresearchthingslikethewaythefactorypositioned,attachedandfinishedfuelclips.”Thespecialhigh-performance290-hp,302-cidZ/28isnotonlyrebuilt,it’s

restored.Inadditiontorunninglikenew,theenginelooksnew.Thepartshavetherightpaintcolors,therightdecals,therightpartnumbers,therightclipsandboltsandtherightfinish.Fechterhadsomerecentlyrestoredenginepartsonhisimmaculateworkbench,includingthealternator.Chevroletprobablyofferedthesamebasicalternatoronothercars,butthoseinstalledon1969Z/28shadaspecialCZmarkingthatisuniquetotheZ/28,becauseitusesaspecialdeep-groovedrivebeltpulley.

RestorerLarryFechterstudiesoriginalphotosandliteratureinordertogettheproperplacementsofallstickers,certificationlabelsanddecals.

ThefullpartsnumbercodeonLarryFechter’s1969CamaroZ/28bellhousingis6858-403.Thehousingisthefactorycorrectbrightredcolor.

ThisbasicalternatorwasinmanyGMcars,butina’69CamaroZ/28,itwasmarkedwitha“CZ”codeandfittedwithadeep-groovepulley.

Fechterstressedthat,evenwithexhaustiveresearchofenginepartsnumbersanddatecodes,it’snotpossibletobe100percentcorrectallthetime.

InZ/28sthesmall-blockV-8bellhousinghad“403”asthelastthreedigitsofthecodestampedonit.

“ThethingI’vefound,whenitcomestoindividualparts,isthatalotoftimes

acarcamedowntheassemblylineand,iftheworkerwasshorttheneededpart,hewouldgrabwhatwasaroundinastoreroomorcratewithoutworryingaboutacorrectdate,sothepartscouldhavebeendatedearlier.Sometimes,thedatesaren’talwaysjustwhatthebooksays—theycouldbeearlierandyoushouldn’tbeupsetaboutthat.Productionsystemswerefarlessscientificinthe’60s.”

Restoredexhaustmanifoldsincludespecificemissionshardwareandinjectortubeholesalongthetopandhavespecificcastingnumbersonthem.

FechterspentweeksrestoringtheoutsideofhisCamaro’senginetohowitwasin1969.“MygoalisalwaystogetitbacktofactoryoriginalasmuchasIcan.Inmyloveofthehobby,that’swhatIenjoydoingoverdrivingorshowingthecar.”Tobringacarbacktohowitleftthefactory,Fechterresearcheshowthecars

wereactuallybuiltandhowpartswerefinishedontheassemblyline.Theexhaustmanifolds1969CamaroZ/28areuniqueandFechterrestoredthe

originals.Themanifolds’distinctionsincludepollutiondevices,emissionshardwareandholesalongthetopfortheinjectortubesthatarepartoftheAirInjectionReactor(A.I.R.)anti-pollutionpump.Themanifoldsalsohavespecificcastingnumbersonthem.

“Myparticularcastingnumbersareweak,liketheywillbeonmanyolderrestoredmanifoldsbythetimeyousandblastthem,”Fechtersaid.“Butthey’resouniqueandrareandoriginalthatIcanlivewiththatlittleinconsistency,butyoucanstillmakethenumbersout.”Inadditiontotheengine,Fechtermadesurethatotherpartsintheengine

compartmentwereabsolutelyastheywerewhennew.The’69CamaroZ/28camewithauniquepowerbrakeboosterwiththenumber“9204”onaverysmalltabontop.Onthebackofthesametabisadateofwhenthepartwasmanufactured.Factorynumbersdidnotindicatemodelyear,soaboostercandatefromlate1968or1969.Anotheruniqueunder-hoodpartoftheZ/28boosteristhattheDelcoMorainenameisstampedupside-down.

TheoriginalbrakeboosterhastheDelcoMorainenameupside-down;knownreproductionpartshavethenamestampedright-side-up.

“Therearemanyreproductionsthatpeopletrytopassoffasoriginal,”Fechtersaid.“Theonesfromthefactoryhavetheupside-downnameandIhavenotfoundamanufacturerwhodoesreproductionswiththenameupside-down.”Anotherspeciallycodedpartisthesmall-block’sbellhousing.Thelastdigits

ofthecodestampedintothebellhousingare“403.”Fechterwasfortunatethat

hiscarretaineditsoriginal“403”bellhousing.Fechtersaidthathiseyeforrestoringanengineandfindingalloftheproper

codes“kindofevolved.”HehadrestoredanumberofcarsbeforeworkingonthisZ/28.Hehadevenrestoredanother’69Z/28threeorfouryearsago.“Ibroughtsomeofmypracticesoverfrommypriorrestorationwork,soit’s

beenaprogressivething,”hesaid.“Butonthisone,there’ssuchdetailthatI’mtakingthingstothenextlevel.”He’sbeenworkingonthecarforatleasttwoyearsandhestillhasawaystogo.Torestoreenginecomponents,Fechterusespaintonsomepartsandpowder

coatingonothers.

Fechterhasfoundthattheletteringontheradiatorhoseshouldbevisibleandthewireandhoseroutingsareproperandcorrectlycolor-coded.

FechterreproducesanyfactorychalkmarksthatCamaroenthusiastsresearchinordertomakehisenginelooklikeafactoryfreshhi-po302.

Fechterusesspecialpaintsavailablefromhobbysourcestoreplicatethefactoryfinishofthebrakeboosterandthecast-ironmastercylinder.

“TheproductsIuseworkhandinhandandlookthesame,”hesaid.“Powdercoatingismoredurable,howeverbecauseiteliminatesnicking.Ihavelearnedtricksovertheyearsandthere’satimeandplaceforbothtypesoffinishes.”FechtercompleteshisownpowdercoatingusinganEastwoodgunanda

double-deckelectricoven.Forpainting,Fechteraddedanupdraftsprayboothtohisshopforpaintingsmallerparts,includingmostenginecomponents.Itallhelpshimattainthatlevelofrestorationheseeks.“Myhobbyisactuallytakingthetimetotakethingsapart,researchthemand

putthembacktogether,”hesaid.“WhenI’mdonewiththistypeofrestorationit’slike,OK,I’mdonewiththat,givemeadifferentonetodo.Itakemytimeandenjoymakingtheengineslookrestored.Thisismytennis,thisismygolf,thisismyfishing,thisismyhunting.”

ApieceofadviceFechterofferstolike-mindedrestorersistocheckforvintagepartsatenginerebuildingshopsthathavebeeninbusinessforalongtime.Nowthat1950sand1960scars(includingmusclecars)havebecomehotcollectibles,thoseexcesspartsfromyearsagomaybevaluablecommoditiestoday.Evenusedpartsthathaven’tbeenrebuiltcanbeworthalotofmoneytothosewhoharvestcoreswithspecificnumbercodes.

The’69Camaroscamewithdifferentexhaustsystemsatdifferenttimes,sothedesignusedtoachieveaproperrestorationmustmatchthebuilddateofthecar.

HEROICFORCERebuildingamassiveWorldWarII-eraFordGAAflathead

V-8

ByBobTomaineRecognizingaFordV-8isprettysimple,unlessithappenstobean1,100-cubic-inchmodelthatputsout500horsepowerinstockform.“It’sactuallydouble-overhead-camforeachhead,”saidBobRubino,ownerof

Mil-SpecVehicleRestorationsinBelvidere,N.J.“It’sfourcamsand32valves,fourvalvespercylinder.”

“It’sahugemotorfortheday,”saidJimKnerr,whorebuilttheFordGAAatMil-Spec.“Iliketotellpeoplethatnowadaystheycanmakea500-cubic-inchmotorwith1,000horsepower.”TheGAA’sdaywasinWorldWarII,anditsrootsareinaviation.“FordmadeanexperimentalV-12aircraftengine,”Rubinosaid,“andthiswas

adaptedfromthat.Theaircraftenginenevermadeitintoproduction,butwhentheyneededatankengine,thisiswhattheycameupwith.”

Mil-Spec’sJimKnerrreassemblestheBendix-StrombergNA-Y5Gcarburetor,whichisamuchlargerthanwhatwould’vebeenonaneverydayFordV-8ofthetime.

TheShermantank,henoted,wasdesignedforaradialenginewithhighhorsepowerandair-cooling,butradialswereneededforaircraft,andthatlimitedthenumberthatcouldbeproducedfortanks.Ford’sGAAwasoneofseveralautomotiveenginestofillthevoid,andRubinosaidthatitendedupastheonewithwhichtheArmywasmostpleased.

“It’sgotlow-endtorque,whichyouwant,andit’sgotsnap,”heexplained.“Theradialsaredogs.They’renotputtingoutpoweruntilthey’reupagainstthegovernor.”Basedonserialnumbers,morethan20,000wereproduced,hesaid,andthe

oneshownherecamefromadonortank.“Itwasamonumentthatwewereabletostripforparts,”Rubinosaid.“That

wasanM4A3Sherman.It’sgoinginanM36tankdestroyer,whichisbasicallyShermanrunninggear,butthehullisdifferent.Theywerebuiltlateinthewar.”TheM36’searlyhistoryishazy,asitwasobviouslyrebuiltfromanearlier

M10tankdestroyerthatwasprobablyaFord.Itslaterhistory,though,isknown.“Afterthewar,”Rubinosaid,“itwasgiventoYugoslaviaaspartofmutual

defenseaid.Intheearly1950s,YugoslaviaeventuallyturnedCommunistandtheiraidfromtheUnitedStatesranoutalongwiththeirsparepartsfortheGAAs.I’massumingthat,becausealloftheseFordenginesweretakenoutandRussiantankenginesoutofT55swereputin.“In1997,afellownamedBobFleminginEnglandbrokeredadealtohavea

bunchofthesetanks.TheBosnianswereusingthemintheircivilwarinthe’90sandwhenNATOwentinandthepeaceaccordwasstruck,thetankswereslatedfordestruction.ThereisonlyahandfulthatcametotheUnitedStates.IwasonthedockinLiverpoolwhenthefirstbatchcamein.Someofthemstillhadtheartilleryammunition—theammunitionforthemaingun—inthem.”RubinohelpedunloadthemandtheM36intowhichtheGAAwillbeplaced

wasamongthem.ItwenttosoutheasternPennsylvaniawhereitwascosmeticallyrestoredandthensoldtoacollectorinNewEngland.Bythattime,RubinohadstartedMil-SpecandcompletedotherrestorationsfortheM36’snewowner.WhenhecompletedaShermanlatelastyear,thetruckthatdelivereditreturnedwiththeM36.HesaidtheM36wasingoodconditionandhadprobablybeenstoredmostly

indoorsbetweenWorldWarIIandthewarinYugoslavia.Heexpectedtofind

mechanicalproblems,becauseofthecombinationofthemorepowerfulRussianengineandtheoriginaldrivelinecomponents,buteverythinghadheldupwell.“Sothisrestorationprojectinvolvesusputtingtheproperenginebackin,”

Rubinoexplained,“whichisalotmorethanjusttheengine.“Theentirewiringsystem’sgottobechanged,thefiresuppressionsystem,the

hullbulkhead.Wehadtogetanotherbulkhead,wehadtogetnewfandrives,weprobablyspentmoretimemodifyingthehull—puttingthehullbacktoitsproperconfiguration—thanrebuildingtheengine.”TheGAAdidn’treceiveanyupgradesduringtherebuild,becauseitdidn’t

needthem,thankstotheengineeringthatwentintoit.“Idon’tthinkanythingwas‘becausewecan,’”Rubinosaid,“becauseitwas

thegovernment,alwaysgoingforthelowestbidder.IthinkitwasjustanaircraftmentalityandIthink,too,that500horsepowerin1942mightaswellhavebeenajetturbineengine.Theydidn’tknowhowtobuildanenginethatcouldhandlethatkindofpower,sotheyknowthey’vegotthismassiveamountofpowerandthey’vegottobeabletoharnessitwithouttheengineblowingapart.“Everythingonthatisonneedlebearings.Thethrottleshaftsforthe

carburetorsareonneedlebearings.Eventhefingersontheclutchpressureplateareonneedlebearings.”“Thethingabouttheengineisthatit’sofahigherqualitythanmostofthe

enginesfrombackthen,becauseitwasaviationthinkingmorethananythingelse,”Knerrsaid.“High-qualitymaterials.Youhaveacast-steelcrankwhereasothersmightbeforged.There’sstuffinthatenginethatyouseetodayas‘modern’inracing.Thewristpindesigncameoutinthe’80sandtheyweresayingitwasarevolutionarydesign.It’stheoldwhat-was-old-comes-around-to-new,buttheyusemodernmaterialstomakeitevenbetter.

EvenaFordfanmoreknowledgeablethanmostwouldbeunlikelytorecognizetheGAAasaFordV-8.

“Thewholeengineassemblywasbalanced.There’saspecinthebookthatalloftherodshavetobewithinthreegrams.Therod-and-pistonassembliesweigh10lbs.each.”TheenginewascompletewhenitarrivedatMil-Spec,Knerrsaid,andthefact

thatitwasinsideofatankhadprovidedsomeprotectionovertheyears.Still,severalGAAsweredisassembledtoensurethathehadthepartsnecessarytorebuildit,andnewcylindersleevesweremachinedbasedonForddrawings.RubinosaidthattheGAAisn’tknownforanychronicweaknesses.“Theonlyrealproblemwiththem—andthisissomethingwe’reprobably

goingtohavetoaddressinthefuturewithmoremodernparts—isthesparkplugs,”hesaid.“Theyfoullikeyoucan’tbelieveandeachtimeyoucleanthem,yougetlessandlesstimebetweenservices.Almost20yearsago,wecouldstillgetthemfromChampionandtheywereover$75aplug.Idon’tknowwhetheryoucangetthemtoday,andIcanonlyimaginewhatthey’dcost.Onthisone,wewerelucky.Ihadbrandnewoldstockplugsforit.”

TheWWII-eraM36wasdevelopedtoprovidethemilitarywithamoreheavilyarmedtankdestroyertodealwithincreasinglyheavyGermanarmor.Itwasarmedwitha90mmgun

andanopen-toppedturret.

TheNOSplugswerefineandtheenginestartedonthestandonitsfirsttry.It’sbeentest-runseveraltimessinceandRubinorecalledthefirsttimehe’drebuiltaGAA.“Igotitstarted,”hesaid.“Itwasrunningreallyniceforprobablynotmore

than10minutesandthenitdied.Ispentthenexthalf-daylookingfortheproblem,onlytofindoutthatthejerrycanwasempty.“Howmuchgasdoesittaketofeed1,100cubicinches?Iknowfromour

experiencethatthisparticularengineinateststandisgoingthroughagalloneverythreeminutes.”

BobRubino,ownerofMil-SpecVehicleRestorations,checkstemperaturesduringatestrunoftheGAA.

GAAshavebeenusedintractor-pullingandKnerrsaidhe’sseenphotosoftheminroadvehicles,buthe’sneverseenonerunning.RubinospokeofatractorwhoseGAAsufferedablock-explosionduringapull,sofueleconomymightnotbetheonlyconsideration.

Whetherit’sarealisticengineforavehicletodayisthusopentodebate,butthepointisthattheGAAdiditsjobasintended.Rubinoemphasizedthatitsprecisiondesigndidn’tpreventitfromholdingup,eventhoughalongservicelifewasn’tthehighestpriorityforaweapon.“Thewholethingwasexpendable,”hesaid,“andyetitwasbuiltassomething

thatcouldberebuiltforever.”

‘57CHRYSLERGETSAMUCH-NEEDEDBOOST

NewbrakeboosterhasSaratogareadytorollagain

Theoriginalbrakeboosterunitinthis1957ChryslerSaratoganeededtobereplaced.Inevitably,rubberpieceswearoutthroughtime,andaMoparunitisbasicallyarubber

accordianthatmovesbackandforthasthebrakepedalisused.

ByBrianEarnestJodyStuckhadahardtimebelievingithimself.ThelongtimeownerofMidwestClassicRestorationsinOneida,Wis.,hasrestoredmorecarsthanhecancount,andworkedonscoresoffinnedMoparsfromthelate1950s,includingground-uprestorationsonmanyofthem.Somehow,though,Stuckcouldn’tseemtorecalleverhavingtodoabrakeboosterswapononeofthebig,beautifulChryslers.“Thismightbethefirst,”hejoked.Thejobofputtingarefurbishedboosterunitina1957ChryslerSaratoga

didn’tturntobeoverlydifficultforStuck.Infact,itwentabitquickerthanheexpected.“IfiguredI’dhavetogetupunderthedashandseewhatwasunderthere,”hesaid.“Withalotoftheseboosters,youhavetodisconnectthingsunderthedashbeforeyoucanpullthemout.Thisonewasn’tlikethat.”StuckknewhewouldhavetoswaptheboosterunitontheSaratogaafterthe

carbeganrunningroughandbrakingpoorly.“Ithadahugevacuumleakandtheenginejustdidn’trunproperly.Wheneveryouhaveavacuumleak,that’samajorissue,”hesaid.“IdidsometroubleshootingwiththebrakesandvacuumcanisterbeforeIfigureditwasthebrakebooster...Itjustranreallyroughanderraticwiththevacuumleak.Wepluggedoffthecanisterandunhookedtheboosterandthentheengineranalotbetter,soweknewwhatitwas.”

Theoriginalbrakeboosterissecuredtothefirewallonthedriver’ssidewithabracketandfourtosixmountingbolts.Onthiscar,themastercylinderisboltedtothesamemountingplate,sothefirststepbeforeremovingtheboosterunitisremovingthemastercylinder.

Afterthat,themountingbracketcancomeoff.

Theboosterhasavacuumhosethatattachestoasmalltankthatstoresvacuumforthebrakes.“Whenwepulledthehoseoffthetank,youcanhearvacuum,soweknowthetankisfine,”Stucksaid.“Buttheunitwasnon-operational,Iguessyoucouldsay.Theboosterfoldsupwhenyousteponthebrakaes.Youthinkof50,60yearsofdoingthat,therubber

justbreaksdown.That’swhathappenedwiththisone.Thisisprobablytheoriginalbooster.”

StuckhadpurchasedarebuiltChryslerbrakeboosterunitfromBoosterDewey(www.boosterdeweyexchange.com)inPortland,Ore.Thecompanycaneitherrestoreanexistingbooster,orsupplyanewunitformanydifferentmodels.InStuck’scase,hewentwithanewunitandwillsendintheoldboosterfromtheSaratogatoberestoredforfutureuseinanothercar.Theboosterswapwasprettystraightforward:unboltthemastercylinderfrom

themountingplateitshareswiththebooster,removetheboosterandbracketfromthefirewall,thenboltinafreshlyrefurbishedunitfromBoosterDeweyunitusingtheexistinghardware.Theaccompanyingsequenceofphotosshowshowhedidit.

Themountingplateandbrakeboosterareremovedtogether.Theplatewillbere-usedwiththenewbooster.Atrightweseetheculprit—alargetearinthebottomsideoftheboosterthatrobbedtheChryslerofengineperformanceandstoppingpower.“Ifyou’veeverdrivenacarwithoutpowerbrakes,youknowhowharditistostop,”Stucksaid.“Whenyoutakeacarthathaspowerbrakesandthepowerunitisnotworking,it’sworseyet.Youputtwo

feetonthebrake,andyou’restillnotstopping.”

ThenewboosterunitfromBoosterDeweyisidenticaltotheoriginalunitandwillboltrightin.“Onthe‘50sDodges,Chryslers,PlymouthsandDeSotos,theyareallmounted[the

same],”Stucknotes.“Theyareallidentical.”

Theoldmountingbracketisboltedtothenewbooster.Stuckwouldordinarilyrepaintthebrackettospruceitup,butinthiscasetheSaratogaisgoingtocomebacklaterthisyearforafullrestoration,sothebracketrepaintcanwait.TheoldboosterunitwilleventuallygetsentintoBoosterDeweyandgetrefurbished—hopefullytogetasecondlifein

anotherMopar.

Ahoseclamppliershelpsremovetheoldhoseclampfromthevacuumhose.

Themountingplateandboosteraremountedbackonthefirewallandthelinkagetothebrakepedalandtheconnectionstothevacuumtankandintakemanifold—whichsuppliesvacuumfromtheengine—arereattached.Whenthebrakepedalisdepressed,theboostercontractsasitshould(left).ForStuck,that’sonebrakeboosterdownandtwotogo.“I’m

workingonthree’57Chryslersatthemoment,andallthreeofthemareinneedofreplacement,”hejoked.

FUELEDBYFRUSTRATIONFixingfaultyfuelgauges

ByWilliamC.“Bill”Anderson,P.E.Thefuelgaugeisoneofanautomobile’smostimportantinstruments.Anaccurategaugehelpskeeponefromrunningoutoffuel,oratleastindicateswhenmoreisneeded.However,somebelievethatcarsgenerategasorthatsomeoneelsewillfillthetank.Doesthatsoundfamiliar?Faultyfuelgaugesareacommonproblemincollectorcars.Sometimesthisis

duetosittinginanunfavorableenvironment,andsometimesitisduetooldage;everythingwearsoutsoonerorlater.And,itisasensitiveinstrument.But,itissimpletotestandmostproblemsareeasytofix.MyexperiencewithfuelgaugeshasbeenprimarilywithGeneralMotorscars,butmuchofwhatfollowsisgenerallyapplicabletomanyothers.Thefuelgaugeiscomposedoftwocomponents:asenderinthetankanda

gaugeontheinstrumentpanel.Thesenderconsistsofafloatonanarmthatvariestheresistancethesenderappliestothecircuitwithgauge.GMcarsfromthe1930stothe1960soperateona30ohmscale.Atzeroohmsinthesender,thefloatisonthebottomofthetankandthegaugeshouldreadempty.At30ohms,thefloatisatthetopofitstravelandthegaugeshouldreadfull.Thesendermustbegroundedtooperateproperly.Thelackofagoodgroundisoftenthereasonthegaugedoesnotworkproperly.

Thewhitewireinthisfuelgaugegroundsthesenderbodydirectlytotheframe.

GaugeReadsFullAtAllTimesIfthefuelgaugereadsfullatalltimes,theprobablecausesare:•Thewirebetweenthesenderandgaugeisbrokenand/ortheconnectionsare

notgood.•Theresistancewireinthesenderisbroken.•Thesenderisnotgroundedand/orthetankisnotgroundedtothechassis.Todeterminewhatiscausingtheproblem:•Removethewirefromtheterminalonthesenderandgroundittothe

chassis.Ifthegaugenowreadsempty,thesenderisnotgroundedorthesenderisbad.•Groundatestleadandtouchittothesendingunitterminalonthebackof

thedashgauge(itisoftenmarkedwitharedpapertag).Ifthegaugenowreadsempty,thewirebetweenthesenderandgaugeisbroken,orthereisapoorconnectionatthegauge.•Removethesenderfromthetankandconnectoneleadofanohmmeterto

thesenderterminalandtheotherleadtothesenderhousing.Then,movethefloatarmandobservetheresistanceasthefloatarmismoved;itshouldvaryfrom0to30ohms.

Iftheforegoingtestsdonotidentifytheproblem,thenthedashgaugeisbadanditmustberebuilt.

GaugeReadsEmptyAtAllTimesIfthefuelgaugereadsemptyatalltimes,theprobablecausesare:•Thewirebetweenthesenderandgaugeisshortedtoground.•Thesendingunitisshortedinternally.•Thefloathasaholeandnolongerfloats.Todeterminewhatiscausingtheproblem:•Removethewirefromthecontactstudonthesender.Ifthegaugenowreads

full,thesenderisfaulty.•Disconnectthewirefromsenderterminalatthedashgauge.Ifthegauge

nowreadsfull,thewirebetweenthesenderandgaugeisshortedtoground.

RepairsRepairingfaultywiresorconnectionsisstraightforward.Toensureagood

ground,Ialwaysinstallashortwirefromthesendertotheframe(notethewhitewireinPhoto1).Ifthesenderisreplacedwithanewunitoranaftermarketreplacement,itis

advisabletocheckthatitperformscorrectlybeforeputtingitinthetank.Usethetestproceduredescribedearlier.Ifthedashgaugeneedsrepair,thisworkshouldbedonebythosewho

specializeininstrumentrepairs;manyofferthisservice.

WilliamC.“Bill”Anderson,P.E.,hasbeeninvolvedwiththeautomotivehobbyformorethan40years.ThroughAndersonAutomotiveEnterprises—www.andersonautomotiveenterprises.com—herestoresandappraisescars.

AIRCONDITIONINGSYSTEMBASICS

Howtokeepanoldcarcool

ByWilliamC.“Bill”Anderson,P.E.Manycollectorcarownerswonderwhattodoabouttheirairconditioning(A/C)systemsasever-changinggovernmentregulationsdictatethetypeofrefrigerantsallowed.In1994,Freon,orR-12,wasoutlawedandreplacedbyR-134aandthatisnowbeingreplaced.Beforeaddressinghowbesttocopewiththesechanges,areviewofA/Csystembasicsisinorder.

RefrigerationSystemTheoryAutomobileA/Csystemsoperateonasingle-stagevaporcompression

refrigerationcycleasshowninFigure1.Refrigerationistheprocessofremovingheatfromaconfinedspaceandtransferringitelsewhere.Thesystemshownusestherefrigeranttoabsorbtheheatfromthespacetobe

cooledandtransfersitelsewhereusingfourmaincomponents:anevaporator,acompressor,acondenserandanexpansionvalve.Thecirculatingrefrigerantentersthecompressorasasaturatedvaporandiscompressedtoahigherpressure.Theresultisahighertemperaturetoasuperheatedvaporstateatwhichitcanbecondensedbycoolingairpassingthroughthetubinginthecondenser.Inthecondenser,thecapturedheatisrejectedandcarriedawaybythecoolingairandtherefrigerantischangedtoasaturatedliquid.Theliquidrefrigerantisroutedthroughanexpansionvalvewhereitspressureisabruptlyreduced,whichresultsintheflashevaporationofpartoftheliquidandloweringthetemperatureoftheliquid/vapormixturetoonethatislowerthanthespacetobecooled.The

coldmixtureisroutedthroughthetubingoftheevaporator.Afancirculatesthewarmairinthespacetobecooledovertheevaporatortubes.Thecirculatingrefrigerantintheevaporatorabsorbstheheatfromtheenclosedspaceandthecyclerepeats.

AutoA/CSystemComponentsFigure2presentsaschematicconfigurationofthetypicalautomotiveA/C

system.Thecompressoristheheartofthesystem.Althoughtheconfigurationofthispumpcanvary,thetypicalcapacityisabout27,000BTUs(BritishThermalUnits)or2“tons”ofcoolingat2,000rpm.Thisisthetypical“average”summertimeheatloadfromthesunandoutdoortemperatureontheexposedsurfacesofacar’spassengercompartment.Thecompressorisbelt-drivenandthepulleysizedsothatitoperatesatabout1,000rpmatidleand6,000rpmat100mphformostcollectorcars.Thepulleyisintegralwithanelectricallyactuatedclutchsothatitcanbedisconnectedwhencoolingisnotdesired.

Theautomotivecondenserislocatedinfrontoftheradiatorandisquitesimilarinappearance.Asthecompressedrefrigerantvaporpassesthroughthecondenserfromtoptobottom,airispassedthroughthefinsandtubingbytheactionofthecoolingfanormovementofthecar.Thetemperatureoftheoutdoorair,thespeedofthefan,andthespeedofthecardeterminetheextentofcooling.Thecooledvaporbecomesaliquidandflowstothebottomofthecondenser

andthenisroutedtothedryer/receiver.Thedryer/receivercontainsadesiccantmaterialthatremoveswaterandimpuritiesfromtheliquidrefrigerant.Theclean,liquidrefrigerantistemporarilystoredwithinthedryer/receiver.Somedryer/receiverscontainasightglasspermittingtheobservationoftheliquidrefrigerantflow.Ifproperlycharged,thereshouldbenoairbubblesvisibleinthesightglass.

Theexpansionvalve,orsometimesafixedorifice,meterstheflowofliquidrefrigerantinresponsetotheneedsoftheevaporator.Itoperatesbysensingthepressureandtemperatureoftherefrigerantvaporleavingtheevaporatortoassurethattheentireliquidrefrigeranthasbeenvaporized.Ifliquidrefrigerantentersthecompressor,damagetothecompressorcouldresult.Thesuctionthrottlingvalve[POA(pilotoperatedabsolute)valve]maintains

theevaporatoratatemperatureabovefreezingbynotallowingthesuctionpressuretofallbelow28poundspersquareinchgauge(psig).Itdoesthisbyspringpressure.Ifpressurerisesabove28psig,thevalveopens,allowingmorerefrigerantvaporthroughtothecompressor.Ontheairsideofthesystem,anenclosurehousestheevaporatorcoilanda

heatingcoilthatissuppliedbyhotwaterfromtheenginethroughwhichacentrifugalsquirrelcagefanpushesair.Airisroutedfromtheoutsideorfromthecar’sinteriorovertheevaporatororheatercoilbyasystemofmanuallyorvacuum-operateddampersandthroughdashandflooroutlets.

Sizingthesecomponentstofunctioninvaryingclimatesfromwintertosummerthroughouttheworldandtobemanufacturedatanaffordablecostrequiredaseriesofcompromises.Thedesignprocesstookintoaccountsurfaceareaofmetalandglassofthepassengercompartment,airflowquantities,compressordisplacement,heattransferareaoftheevaporatorandanticipatedconditions,plusenginespeed,outdoortemperatures,humidityandheattransferthroughglass.Throughthedesignprocessandtestingofthesystem,theengineersdeterminedtheactualperformanceofthesystemundervaryingtemperatureandhumidityconditions.Mostshopmanualsprovidethisdatafor

diagnosisofsystemperformanceandproblems.Thewarmertheoutsideairandthehigherhumidity,thegreatertheloadappliedtotheA/Csystem.Asthetemperatureclimbs,particularlyoverthecondenser,thecompressorhastoworkharderandisabletocirculatelessrefrigerant.Withlessrefrigerantcirculating,thesystemhaslesscapacitytocooltheairbeingforcedovertheevaporator.And,ifhumidityishigh,ittakesevenmorerefrigerantcirculationtocoolanddehumidifytheair.

RefrigerantsTheidealrefrigerantwillhavefavorablethermodynamicproperties,benon-

corrosivetosystemcomponents,andbesafe.Whilemanychemicalscanberefrigerants,notallpossiblechemicalsareideal.TheautomotiveindustrysettledonFreon(R-12),achlorofluorocarbon,becauseitwasnon-flammableandnon-toxic,anditsthermodynamicpropertieswerebestsuitedforthepracticalconsiderationsofautomobileA/Csystems.Itwasusedfromtheearliestdaysuntil1995.Then,itsusewasoutlawedbecauseofitspotentialtodepleteatmosphericozone.ThereplacementrefrigerantchosenbecauseofitsminimalimpactonozonewasR-134a,ahydrochloroflourocarbon.Mostrecently,globalwarmingconcernshavedictatedabandoningR-134a.ThelateststandardsrequireautomotiveA/Csystemstousearefrigerantwithaglobalwarmingpotential(GWP)of150orless.TheGWPofR-134ais1410.

ImpactsonCollectorCarsMostoftoday’scollectorcarswithA/CsystemsweredesignedtouseFreon,

whichwasoutlawedin1995,withallcomponentssizedtoavehicle’sthermodynamicproperties.Also,since1995,thoseworkingonautomotiveA/CsystemsmustbecertifiedbytheU.S.EnvironmentalProtectionAgency.Additionally,itisillegaltoventarefrigeranttotheatmosphere.So,itisbesttoleaveA/Cworktothosecertified.However,ifacertifiedtechnicianevacuates

therefrigerant,anyonecanremoveandreplaceA/Ccomponents.Chargingtherepairedsystemmustalsobeperformedbyacertifiedtechnician.Whiletheprimaryconcernsaretherefrigeranttypeandmaintainingaproper

charge,evena1993caris20yearsold.So,IrecommendedthatifsomeworkontheA/Csystemisneeded,theentiresystemshouldberestoredtoas-newforoptimumperformance.Specialistsexistthatcanrebuildexistingunits,andfunctionalreplacementsexistifoneisnotconcernedaboutauthenticity.ThereplacementrefrigerantcanbeFreon.ItisstillavailabletoEPA-certified

technicians,althoughsomewhatexpensivecomparedtoR-134a($13to$20perpoundvs.$3.50to$4perpound).Additionally,giventhat20yearshaselapsed,notallshopshaveretainedtheequipmentneededtohandleFreonasitcan’tbemixedwithR-134a.However,usingFreonwithafullyrestoredsystemensuresthatitwillfunctionasitdidwhennew.Today’scommonrefrigerant,R-134a,canbeusedinasystemoriginally

designedforFreon.However,itisnecessarytochangetheoilinthesystem.AutomotiveA/Csystemscarrytheoilneededforessentialcompressorlubricationwithintherefrigerant.R-134arequiresasyntheticoilcontainingestersinsteadofmineraloilusedwithFreon.ItisalsonecessarytochangethefittingstoacceptR-134achargingequipment.EarlyadviceonconversiontoR-134asuggesteditwasnecessarytochangethesystemsealsandhoses.Experiencehasproventhisnottobetrue.Additionally,ithasalsobeenestablishedthatasystemdesignedforFreonshouldbechargedto90percentofitsfullcapacitywithR-134atoobtainoptimumperformance.Shopmanualsprovidesystemrefrigerantcapacitiesandoilquantities.ThedownsideofusingR-134ainasystemdesignedforFreonisa10to20percentreductionincoolingcapacity;somesayitisasmuchas30percent.Thismayormaynotbeasignificantissue,dependingonhowthecollectorcarisusedandtheoperatingambienttemperatureconditions.

Summary

Collectorcarairconditioningsystemswillbenefitfromacomprehensiverestorationtorestoreoptimumperformanceandeliminatenaggingrefrigerantleaks.Freon,thedesignrefrigerantformostofthesesystems,remainsavailableandwillmaximizeanoriginalsystem’scoolingpotential.R-134arefrigerantcanalsobeusedifappropriateproceduresarefollowed.Therearenoothersimplereplacementrefrigerants.Whilethereareotheravailablerefrigerants,theirinstallationrequirespreciseservicingtechniques.

SECTIONFOUR

GENERAL

THEPRANCINGHORSESTABLEForFerrariowners,MotionPerformancehasbecomethe

goldstandard

ByAngeloVanBogartFromasmallWisconsinshed,WayneObrygroomedhisrestorationbusinessover35yearsintoapreeminentFerrarirestorationsourcewiththeworld’shighestaccoladestoitscredit.Nearly50employeesnowrolloutasmanyassixcompleteFerrarirestorationseachyearfromthethreebuildingsthatmakeupMotionProductsInc.(MPI)inthehuddledcityofNeenah,Wis.AndeachofthoserestorationsisworthyofthelawnsatthePebbleBeachConcoursd’ElegancetoItaly’sConcorsod’EleganzaVillad’Este.HowObryevolvedfromaone-stallshophousingaJaguarin1979toaworld-

renownedFerrarirestorationshopwiththousandsofsquarefootagecanbepinpointedtoonecustomer,accordingtoMPIprojectmanagerDustinWetmore.“AguynamedJoeMarchetti(ofInternationalAutoInc.)thatdidalotof

Ferraridealingandservicehad[Obry]pickupacar,anditwasbasicallyjustausedcarspiff-up,”Wetmoresaid.“Marchettisaid,‘Ifyoudogoodforme,we’llkeepsendingyoucars.Ifyoudobadforme,you’llnevertouchanotherFerrariagain.’”

RestoredcarsshowcasedatMPI’s2013openhouseincluded,fromlefttoright,aone-off1953Ferrari375AmericaCoupeSpeciale;1951Ferrari340AmericaCoupe,1952Ferrari

342AmericaCabrioletandaone-off1954Ferrari375PlusCabrioletSpeciale.

Obry’sworkwasclearlymetwithsatisfaction,andmoreredheadswearingtheprancinghorsegallopedintotheshop.However,WetmoresaidthatitwasaFerrari250LongWheelBaseCaliforniaSpiderrestorationthatputMPIontheradarofFerrariownersaroundtheworldabout20yearsago.ThatFerrarimadeasplashatthePebbleBeachConcoursd’Elegance,anditwasthefirstswingofaone-twopunchthatbroughtMPItotheforefrontamongFerrariowners.“Theeventthatsolidified[MPI]wasaFerrari212exportwithaPininFarina

bodytheyrestoredandbroughttoPebbleBeachthatendedupbeingthefirst100-pointFerrariatPebbleBeach,”Wetmoresaid.“Oncethathappens,youprettymuchcan’thelpbutbenoticed.”Maintainingsuchahighlevelofqualityoftenmeanscontrollingmanyofthe

aspectsofrestoration.FacedwiththeneedtoreproducetheunobtainablerarevintageFerraripartsrequiredfor100-pointrestorations,MPIsoonbegancreatingpartsforitsprojects.Today,theshopcanbuildalmostanythingthatarestorationrequires,whetheritbeforaFerrarioranyoftheotherdomesticorforeigncarsitrestores.

A1962Ferrari400SuperamericaCoupeLongWheelBaseinthefinalthroesofreassembly.

“Withourcadcamcapabilityand3Dscanningandlow-volumemachining,wehavetheequipmenttomakeparts,”Wetmoresaid.Someparts,suchasemblems,aremadeoneatatime,whileotheritems,suchascastenginepartsordistributors,maybemadeinmultiplesandaddedtoinventory.Thosepartsarethenmadeavailableasneededtocustomersorotherrestorers.MPI’scapabilitiesareusedonmorethanitssixorsocompleteFerrari

restorationsperyear.Atanytime,thereareabout50carsamongMPI’sthreebuildings.Somewillreceivefullrestorations,butmostwillreceivepartialrestorations,mechanicalbuilds,maintenanceworkoracombinationoftheseservices.ThecarsandtheworkthatbringsthemtoMPIareasdiverseasthebusiness’

skills.AmongthecarsonhandrecentlywereaDatsun240Z,aCamaroresto-modandaMercedes-BenzGullwing.Beforeeachleavestheshop,itwillbe

thoroughlytested.NocarundergoesmorescrutinythanonethatreceivesacompleterestorationinthecareofMPI.ThereisastrictprocessforcarsthatreceivefullrebuildsatMPI.Onceacar

entersthedoors,thestaffatMPIhastheownerfilloutwhatheexpectsfromtherestorationtoreflecthowthecarwillbeused(pointsand/orconcours-judged,racecar,driver,etc.).Thecarisassignedajobnumbertoidentifyitanditspartsandaroughscheduleofmilestonesforprogressisdetermined.Then,itisimmediatelyplacedintoObry’sexperiencedhands.Foranentireweek,Obrydrivesthecartoandfromtheshop,makingnotesregardingavehicle’sweakpointsthatwillneedtobeaddressedintherestoration.“Thatwayweknowwhatwearegettinginto,”Wetmoresaid.“Hecan

determinethebrakeandsteeringperformance.Anydriveabilityconcernisnoted,nomatterhowminiscule.Thenwe’lldoafullelectricalevaluationandwe’lllookitovertoseeifanypartsareincorrect...sowecancomeupwithalistofpartswemayneedtoreplace.Webasicallyhavetovetallthecomponentsofthecartorestorethecarascorrectlyaswecan.”Thecaristhenresearchedtoensureitisauthenticallyrestoredwhileit’s

componentsarethoroughlyphotographedrightdowntothepartnumbers,bulbs,lensesandengravings.Ifthereareincorrectcomponents—andinthecaseofFerraris,manyhavebeenupgradedwithlaterparts—MPIreplacesthemwithrestoredparts,orpartsitmustmake.Thesubjectcarthengoestothededicateddisassemblyroom,whereitistorn

down.ComponentsthatmustberestoredaresenttovariousareasofMPIsothatwhenthechassisandbodyarepainted,thepartsarereadytobere-installed.“Oncewehaveaworklistputtogether,westartmetalrepairsandwhileall

thatisgoingon,theengineisbeingrebuilt,thetransmissionisbeingrebuiltandthecomponentsaregettingrebuilt,”Wetmoresaid.“It’ssuchahugeadvantagetohavethosepartsdoneandwaitingtogowhenthebodyisdone.Wetrytotaketheexperiencethatadealershiplinetechwouldhave.Wetrytotakethatkindof

mentalityandthatkindofthinking.Thatway,attheend,therearelesssurprisesandlesschanceoferror.”

A1960Ferrari250SeriesIIPininFarinacabriolet(left)anda1962Ferrari250SeriesIIPininfarinacabrioletarebeingrestoredsimultaneouslyfortworelatedmen.

Thecar’scomponentsallofthewayuptotheenginearealsotestedontheshop’sdynosbeforetheyareinstalledonthecar.Thismethodologyensuresthecomponentsarefullysortedbeforetheygointothecar,thusavoidingpotentialscratchesordamagetofreshpaintandbodywork.ThewholerestorationprocessonaFerrariinaverageconditioncantakeas

littleas12months,acredittoMPI’sefficiencyandexpertise.Thefinalstepisaroadtestthatensuresthecarisreadytobedeliveredtotheowner,whetheritbeonashowfield,racetrackortohishome.AsMPIexpandsitsexpertisetoLamborghiniandadditionalforeignand

domesticmarques,expectthosedaysofthetinyshedtolookmorequaintby

eachaccoladewitheachpassingyear.

MOTIONPRODUCTSINC.8540StateRoad76Neenah,WI54956920-725-4688

www.mpi-ferrari.com

KEN’SKLASSICS:OFFTHEBEATENPATH

High-endrestoshopisahiddengeminDairyland

StoryandphotosbyBrianEarnestWhoeversaid“locationiseverything”whenitcomestorealestateprobablyhasn’tbeentoKen’sKlassics.Tobefair,theaccomplishedandaward-winningclassiccarrestorationshopisn’texactlyinthemiddleofnowhere,butasthejokegoes,youseenowherefromthere.Somehow,ownerandfounderKenStadelehasturnedwhatshouldbehis

shop’sbiggesthurdle—thefactthatit’srunfromanunassuminglittlebuildinginthemiddleofruralWisconsinfarmcountry,manymilesfromthenearestdecent-sizedcity—intooneofthecompany’sbiggestcharms.Whenyoubringyourcollectorcartotheshop,locatedjustoutsidethetinycommunityofMuscoda(pronounced“Muss-ka-day”)youcouldprobablyparkitoutfrontandleavethekeysinwiththemotorrunningandeverythingwouldbejustfine.

Ken’sKlassicshasalonghistoryoftacklingbigpre-warClassicmachines,butitcanhandlesmallertoys,too,suchasthis1969Datsun2000roadster.

“AlotofpeoplethoughtIwaspossiblybarkingupadeadtree,becauseMuscodaisnotexactlythecenteroftherestorationfield,”Stadelerecallswithalaugh,thinkingbacktohisdecisionin1981tosellhischemicalstrippingbusinessinMilwaukee,Wis.,andstarthisowncollectorcarventurebackonthefamilyfarm.“Butthenicethingaboutrestorationsthattakelongerispeoplearemorewillingtotravel.PeoplearenotgoingtocometoMuscodatodoa10-hourjob,butwhenyouaredoingseveralthousandhours,theydon’tmindtraveling.

KenStadeleopenedKen’sKlassicsinruralMuscoda,Wis.,morethan31yearsago.Almostsincethebeginning,theshophasspecializedinhigh-qualityrebuildsofhigh-end

collectorcars.

“Fortunately,ithasallworkedout.”Thebusinessgamblehasdonefarmorethanjustworkoutforthefriendlyand

chattyStadele.Ken’sKlassicshaslongbeenoneoftheleadingClassicandprewarrestorationoperationsintheMidwest.Thehitlistofcollectorcarsthathavecomeandgonefromtheshopislongandimpressive:rarePackardsandPierce-Arrows,Cords,Auburns,Ferraris,Rolls-Royces,Cadillacs,Lincolns,Porsches,Jaguars,HemiMopars,vintagemusclecarsand1950sfavoritesofallflavors.Stadele’sresumewouldbetheenvyofalmostanyshop.Ithasallgonethewayhehadhopedwhenheandhiswife(thengirlfriend)

Debbielaunchedthebusiness31yearsago,mostlybecauseStadelehasstucktohisvisionforasuccessfulandsustainablerestorationbusiness.“EventhoughIgetmostofmyworkoutofcities,Ijustlikecountryliving,so

Ihadthevisionofbuildingashopbackhereanddoingrestorations,”hesaid.“Thelandwasprettyeconomical(laughs).Thiswaspartofourfarm!Andtherewasnozoningherebackthen.Onedaywehaddairycowsonthisland,thenextdaywehadbulldozers.”Partoftheconstructionprocessinvolvedbuildingahomethatisattachedto

theshopandoffice.DebbieandKenhavelivedtheresincethedoorsofthebusinessopened.Theonlyrealchangecamebackin1999whena1,500-squarefootadditiongavethecrewsomemoreroomtooperate.Kenalmostcertainlycouldhaveexpandedfurtherandkeptaddingemployees,butthatwouldhavegoneagainsthisgutinstincts.

This1956Mercuryisreadytostartbeingreassembled.Thebodywork,paintandframearealldoneandreadytobereunited.

This1957ThunderbirdcametoKen’sKlassicsforafullground-uprestoration.Itawaitsanewinterior.

“I’mkindofafirmbelieverthatbiggerisn’talwaysbetter,”Stadelesaid.“IknewthatwiththisamountofsquarefootageIcouldn’tdoitonmyown,andIknewIneededtohaveaminimumofthreeorfouremployees,andmaybeamaximumofsevenoreight.Currentlywehavesixguysherefulltimeandonehalftime.”Rightfromthebeginning,Stadelewasabletospecializeinhigher-endcars

andprewarClassics.Hesoongainedareputationforturningouthigh-qualitycarsandthephonehasn’tstoppedringingsince,withcustomersshowingupfromalloverthecountry,andevenoverseas.Allthewhiletheformulaforsuccesshasremainedthesame—don’tcompromiseonquality,befairandfriendlytoeverybody,anddon’ttakeonajobunlesstheshopandthecustomerareonthesamepage.ThatrecipehasbroughtonegreatcarafteranothertoMuscoda,usuallyforafullground-up,factory-correctrebuild.“WedoverylittleofwhatIwouldcallnon-stockrestorations,”Stadelesaid.

“WhenIstartedoutherein1981,Ithinkthesecondjobwedidwasa’33PackardSuperEightconvertible,anditwasforasministerfromDubuque[Iowa].WhenIfirststarted,itwasbasicallyallpre-warcarsandIstillenjoythelooksofthePackardandAuburnsandPierce-Arrowsmorethansomeoftheothercars.That’skindofwhatwe’reknownfor.Iwouldhavetoadditup,butIthinkwe’vedoneeightor10Pierce-Arrowsandtherejustaren’talotofthoseoutthere.“We’vedonesomestreetrods,andwe’vedonesomestreetrodsthatwere

builtyearsagoandtheycomeinforafresheninguporarepainting,butwe’rereallynotintotheexoticstreetrodsandthechassisthatarejustsooverthetop.That’sawholeotherballgame.”

A1957ChevroletBelAirawaitsfinishingtouchesintheshop’sassemblyroom.

Stadelesighsalittlebitwhenhetalksaboutalotofthe“messy”projectcarstheshoptakeson.Quiteoften,heandhiscrewhavetoridetotherescuebecauseanothershophasdroppedtheball.“Ineveractuallycounted,butbetweenhalfandtwo-thirdsofthejobswedocomeoutofothershopswherethey’veeitherlostinterestorgoneunder,orrestorationsthathavestoppedforonereasonoranother,”hesays.“Ihaveeightorninecarshererightnow,andfiveofthemhavecomeoutofothershops.“Therearesomecustomersthathavestartedabigprojectandmaybeit’s

somethingthey’veneverdonebefore,andsometimestheygetoverwhelmedandmovefromonelocationoranother,ortheyneedthemoneytoputakidthroughschoolandtheyhavetostoptheirproject.Wegetalotofprojectslikethatthatjustgetabandoned.”’Asidefromchromeplating,upholsteryandheavymachining,theshophandles

everythingin-houseandStadele’screwclearlymarchesinlockstepwithhismeticulousattentiontodetailcarefulorganization.Theshopisbrightandclean,andthereishardlyatooloutofplace.Thesix-mancrewallwearsmatching

blackKen’sKlassicsshirts,andtogetherthesixhavemorethan100yearsintherestorationbusiness.T.J.Krueger,theshopforeman,hasbeenwiththebusinessalmostsincethe

dayhegotoutofschoolin1986.Heistheshop’smainpainterandoneofthebigreasonsKen’sKlassicshasearnedareputationforturningoutpaintjobsthatmatchthehigh-endcarsthatcomeoutoftheshop.“Everybodyherehastheirstrengths,andeverybodycanpainttoacertainextent,”Stadelesaid.“Wetrytoputroundpegsinroundholes.T.J.isanoutstandingpaintersohedoesmostofourpainting.“Mostpeople,whentheygotoacarshow,thefirstthingthatpeoplewillsee

ornoticeisthepaint.We’rekindofknownforourhigh-qualitypaint.WearePPGcertifiedfromthefactory,andeverythingwedoisstrippeddowntothebaremetal.Weneverpaintoveranything,sowhenwestripstuffdowntobaremetal,usetheirproductsfortheprimersandallofthat,basecoat,clearcoat,thenpeoplegetalifetimeguarantee…That’sthewayweliketodoit.”Inthecompany’searlydays,Kenwasahands-onowner,workingonthecars

andspendinghisdaysintheshop.Thosedaysarelonggonefortheboss,however.Hestaysbusyrunningtheshop,liningupcars,visitingownersandtravelingtoseecars.“Afteryougetafewemployeesyouneedmorecarstokeepthebusinessandsomyjobmovedintotheofficefulltime.Imissit,butIprobablyhaven’tpaintedacarfor35years,”hesaid.“Ienjoymeetingthepeople.That’sthepartIenjoymost.”Thevastmajorityoftheworkintheshopinvolvescustomer’scars,butthe

bossbringsinaprojectofhisownonceinawhile,too.“I’vegenerallydoneacarformyselfeverytwoyearsorso.Ilikethehunt,findingabasketcaseandfixingitup.Ienjoyfindingthem,fixingthemup,thensellingthemandstartingallover.”

Atwo-tonegreen1940DeSotosedanisalmostreadytoreturntoitsowner.

Stadeleoftenhastohittheroadtogovisitwithownersandcheckoutpotentialprojects.Hesaysherolledupbigmilesinhis2008Corvettethissummermeetingfacetofacewithcarownersanddiscussingplansfortheircars.“ItrytosetupanappointmenttoseeavehiclewhereIcangototheirlocationandseeitinperson,”hesaid.“Ialwayslikehavingthecustomerandthevehicleandmealltogethersowecankickideasaroundtogether.”Asofteconomyinrecentyearshasledtoevenmoremilesandmoreroad

trips.Stadelefrequentlytravelsonweekendstosetupdisplaysatcarshows—sometimesbringingaprojectcarwithhim.“Ihaven’treallynoticedthatmuchofadownturn,”henoted.“Peopleare

moreselectiveabouthowtheyspendtheirmoney,butweAmericans,weloveourcars.It’snevergoingtototallycease.Itneverwill.”

ThatmeanstherewilllikelybeplentyoffancycarsvisitingMuscodaintheforeseeablefuture.“Ireallydon’tseeusbranchingintoanythingnew,Ireallylikedoingfull

restorationsandthat’sreallyourbreadandbutter.I’m61yearsoldandIdon’tplanonstartingsomenewventure,”Stadelesaid.“Ilikewherewe’reat.I’mnevergoingtoretireandmovetoFlorida.Andthe

nicethingisIcangotothecityandbringtheworkbackhere.There’sreallynoneedtomovetoametropolitanareaoranything.”

SOURCE:Ken’sKlassicsMuscoda,Wis608-739-4242

www.kensklassics.com

BOBPERKINS:THE429BOSSMAN

Shopsetsbarsky-highforMustangoriginality,concoursquality

ByBrianEarnestandphotosbyKrisKandlerThedoortothesouthendofBobPerkins’shopswingsopen,andtwogrinningstrangerswalkinunannounced.“Canwesee?”asksoneofthemenwithasoutherndrawl.“Sure,youcanlookaround.Thecollectionisoverintheotherbuilding.I’llbe

overinalittlebit,”Perkins’.“We’refromGreenville,S.C.,”thestrangercontinues.“Wejustwantedtostop

inandmeettheguru.”ThestrangersstopshortofaskingforPerkins’autograph,butyougetthe

feelingtheyatleastconsideredsucharequest.Clearly,theyhavemadePerkins’shopadestinationonthisday,andmeetinghimwillbethehighlightoftheirvisit.

BobPerkinshasassembledafabulousdisplayoflow-mileageMustangsathisJuneau,Wis.,shop,includingthisultra-pristine1969Mach1(oppositepage).Perkinshasbecome

wellknownovertheyearsforhigh-endrestorationsonBoss429s.

It’snotoftenyou’llseeapairofBoss429sinthesameshop.TheredTascaFordcarontheleftisalmostdone,whilethecarintheairisgettingextensiveundercarriagework—a

trademarkofPerkins’restorationwork.BelowisaformerBoss429dragcarthatisgettingreturnedtoitspastglory.

SuchislifewhenyouhavescaledtoloftyheightsintheMustangworld.Evenwhenyouhideeveryday“outintheboonies,”asPerkinslikestosay,eightmilessouthofthesmalltownofJuneau,Wis.,ponycarfanaticswillcomeandfindyou.NotthatPerkinsisnecessarilyavoidinghisMustangbrethren.Heknowshehandleshigh-profilecars,oftendealswithwealthyclients,frequentlywritesforapopularhobbymagazine—MustangMonthly—andgenerallydoeshigh-profileworkwhenitcomestorestoration.Butbeingcalleda“guru”clearlymakeshimalittleuncomfortable.“That’sno

bigdeal.I’vebeencalledworse,”hesayswithagrin.“Alotofitisbecauseofthemagazinestuff.That’showyougetexposureandstuff.“Ihavealotoffriends,andifI’maguru,thenthey’reallgurus,too.

Everybodyhastheirniche.”

Perkins’nicheinthewideworldofMustangsisthe“BossMan,”asinBoss429s.Whetherheiscomfortablewiththetagornot,thefriendly,low-keyWisconsinitehasearnedhisreputationastheguyyouwantdoingyourrestorationifyouownoneofthefamedBosses,whichwereatoratleastnearthetopofthemusclecarmountaintopwhentheywerebuiltin1969and’70.Perkins’littletwo-and-a-half-manoperationhasbeenturningheadsandturningoutaward-winningrestorationsformorethanthreedecades,andtherearenosignsthatdemandforhisworkisslowingdown.Perkinswasdefinitelyaheadoftherestorationcurvebackin1980,whenhe

turnedaGrabberGreenBoss302intoanastonishing500-pointshowcar.Hisworkdetailingandperfectlyreplicatingthecar’sundercarriage—flyinginthefaceofconventionbymakingitidenticaltothewaythecarsappearedwhentheycamefromthefactory—wasgroundbreakingandchangedthewayhigh-endMustangrestorationsweredone.Andnotonlywasheabitofavisionarywhenitcametothecorrect

appearanceofthecars,butPerkinswasalsoabletopredicthowvaluableNOSpartswouldbe.TogetherwithfriendandbusinessassociateJimCowlesofGreenBay,Wis.,Perkinsspentaboutsevenyearsassemblingastaggeringinventoryofstill-in-the-boxFordpartstosupplementhisrestorationwork.“Itwasreallyjustahobbyandapassionthatturnedintoajob,”hesaidofhis

unlikelytransformationfromhighschoolpoliticalscienceteacherandtrackcoachtocelebratedMustangrestorer.“Partofitwas,youknow[beingin]therightplaceattherighttime.IfIwantedtostartoveranddothisnowfromscratch,itwouldn’tbepossible,becauseabigpartofoursuccess,Iguess,atthecarshowlevelanyway,isbecauseofallthenewoldstockpartsthatwehadthatwewereabletogatherupintheearly’80s.Regardlessofyourbudgetnoworhowmuchmoneyyouhad,youjustcouldn’tduplicatetheinventorywehave,andIthinkthatgivesusalegupontherestoftherestorationshops.”Perkinscanbeselectiveabouthisworkthesedays,andheis.HerestoresBoss

Mustangsalmostexclusively,andtheyarealmostallground-up,no-stone-

unturned,concours-qualityprojects.Heturnsawayfarmorecarsthanhetakeson,andhedoesitwithoutahintofego.Withhisworksellinghisleftoverpartsfromhisinventory;writing;judging;runninghisownlittlemuseum-likeshowroomthatdisplayshisownamazingcollectionofMustangandFordparts,automobiliaandSchwinnbicycles;andplayingfathertofoursons,thereisonlysomuchofhimtogoaround.“TheBosscarsarealwaysgoingtobeourniche,andeveryonceinawhile

I’llgetsomebodythatwilltemptuswithareallyrareShelbyorsomething,”Perkinssaid.“Wedon’treallyneedanyextrastuff—peopleknowwhoweareandthenwhenyougetoutofyourareaofexpertise,youhavetostartdoingresearch,andIdon’tthinkyoushouldeverchargeacustomerforresearch.Wetrytostayrightwherewe’recomfortable.OntheBoss429s,wedon’tneedtoresearchanything.”PerkinsfirstbecameobsessedwithearlyMustangsduringhiscollegeyears,

andheboughthisfirstBoss429in1972afterhissecondyearatDrakeUniversity.Fromthere,onecarledtoanother,anditwasn’tlongbeforehedevelopedanaffinityforfindingandstockpilingparts,andageneraldisdainforrust.“Youstarttorealizethatoncethey’rerusty,they’reneverthesame,”hesaid.

“IstartedbuyingstuffdownsouthandinCalifornia.Ijustdidn’twantanythingthatevenhadsurfacerustonthefloorpans,andwekindofgotspoileddoingthat.SincethenI’veneverreallyworkedonanyrust.Youworkononerustycarandyoudon’treallywanttoworkonanyotherones.”PerkinsgotintoshowingcarsafterheboughthisGrabberGreencaranda

1967ShelbyMustang.Whenheearnednotorietyforthosecars,therestorationworkthathehadbeendoingonthesidegrewtothepointthatheeitherhadtostartturningdownalotofmoneyintherestorationbusiness,orheneededtoquithisteachinggig.Hechosethelatter.“Monetarily,itwasn’tthatbigadecisionbecauseIwasmakingmoremoneyonthesidedoing,like,painting,likeIhadbeendoingasakidinthesummer,”hesaid.“Andwiththecarstuff,Ijusthad

enoughpeopleaskingmetodostuffthatIfiguredtherewasenoughoutthereforwork.Iwasdoingstuffontheside.“Thenrightawaythat[greenBoss302]wasinMustangMonthly,andpeople

foundoutaboutthecar.That’skindofhowitallstarted.Theotherthingiswe’vealwaysbeenkindofattheforefrontof,youknow,takingittothenextlevel.Backin1980whenwetookourfirstcarout,nobodyintheMustangClubofAmericawasdetailingtheundercarriageofthecar,andweprobablyspentmoretimeonthefloorpanthanwedidontheexteriorpaintandbody,whichyoucanstilldotoday.Ithinkwe’vealwaysbeenatthefrontofthat,andwe’vebeenluckythatpublicationslikeMustangMonthlyand[OldCarsWeekly]…havefeaturedourshop.Ithelpstohavealittlebitofextraexposurelikethat.

OneofPerkins’personalfavoritesisthisoriginalorange1970Boss302.“I’vehaditsince‘81hesaid.“Iwouldn’tsellthatone.Thatwouldbethelasttogo.”

Themoreyou’reintoit,itdon’tmatterifit’scarsorpartsorbicycles,themoreyou’reintoit,themorethingsyoufallinto.”Perkinscertainlydidn’t“fallinto”hispartsempire,however.HeandCowles

accumulatedroomsfullofpiecesthehardway—drivingfromdealertodealerbetween1981and1987andbuyingalmostanyNOS1960sFordandMustang

piecestheycouldgettheirhandson.Well,atleastasmuchastheycouldaffordatthetime.“We’dgooutwith$500,$600dollarsapiece.We’dhavehisvan,andmy

trailer,”Perkinsrecalled.“Heliked’65and’66stuff,andIliked’69and’70,sowedidn’thavetoworkhardtosplitthestuffup.“SayIwasgoingtoAlbuquerqueforMustangNationals.I’dhavemypath

laidout,andIcircledallthedealers,andI’dgothewaywhereIcouldhitthemostofthem…I’dleaveJiminthevanmostofthetime,andI’dgoinandtalktothepartsmanagers.Onceyouconvincethemyouweren’tintherejusttearingstuffapart,they’dusuallyletyouin.Iwouldn’ttelltheownersitwasjustMustangs,I’djustsayIwaslookingforoldFordpartsandthatwewereintherestorationbusiness.I’dbeafterbelts,andhosesandgasketsand‘Idon’tlikeaftermarketpiecesandI’llpayyouwhateverisinyourbookforpricesandI’matyourmercy.’I’dalwaystrytotellthemIwasn’ttryingtogetitfornothingandmakethemfeelcomfortable.Thebigthingwas,wenevermadeamess,andIneverhadanytroublegoingbacktosomebodyasecondtime.Iwasrealcareful,andwetriednevertomakeanybodymadatus.Someguysouttheregotodealerslookingforparts,andtheymakeamessandleave,andtheyjustruinitforthenextguy.“Itwaslikeabuildingstartingfromscratch.Youbuy10pieces,youkeeptwo

andyouselleightandyougobackoutandyoubuilditalittleatatime.”Thepartsstashispartcollectionandpartinventorythat’savailableforsale.

PerkinsdabbleswithlistingvintageNOSFordpartsonline,and“occasionallyIthrowsomethingreallycoolonthere,”hesaid.Hedoesn’tkeeptrackofhispartsonanykindofinventorysystemorspreadsheet,andhedoesn’tlistwhathehasavailable.Hedoesn’tseetheneed.“They’lljusthavetocallme,”hesaid.“It’sallinmyhead.Idon’talwaysknowhowmanyofeverythingIhave,butIknowifI’vegotoneortwo.”Perkinshasbeeninhiscurrentfacilityfor18years.Hehouseshisown

collectionandmuchofhisdizzyingarrayofpartsandmemorabiliaononeend

oftheL-shapedbuilding.Ontheotherendarehisrestorationareasandroomsthathousecarsinvariousstatesofrenovation.Onthisday,twoBoss429saregettingworkedon.OneisanearlycompletecarthatPerkinsisjust“detailing”asafavorforacustomer.Theotherisashellsuspendedonarotissierie.TheysharearoomwithoneofPerkins’owncars—ablack429awaitingacompleterestoration.ThatcarwillgetthefullPerkinstreatment—itisthefirst429everbuiltanditwillbeworthbigmoneyifheeverwantstosellit.Perkinsfigureshe’srestoredabout15Boss429s,“andI’veprobablyowned

50or60ofthem,”hesays,withmanyturningintoprolifictrophygettersandconcourswinners.Perkinstypicallytakesayear,giveortakeamonth,tocompletelyre-doacar.“We’vedonesomuchofthesamethingonthese429s,wecangive

[customers]thesamequoteonwhatthelaborwillbe.Wedon’tevenkeeptrackoftime,wejustchargethemfor1,000hours.Mostofthecarswegetinaresuchnicecars,werarelyhavetodoanyweldingonthem.Therearenomajorstructuralrepairsonthem.Iknowwhatittakestostripthemandeverything.Ifwekepttrackofeverything,nobodycouldaffordtohaveonedoneifyouchargedthem85bucksanhour.

PerkinskeepssomeofhisoriginalFordproductinventorydisplayedforvisitors.MostofhisFordmemorabiliaandNOSpartswereacquiredfrompartsmanagersatForddealers

aroundthecountry.

“Materialsareextra,sowedon’thavetoworryaboutskimpingonsomethinglikepaint.Anyshopthatwillguaranteeacompleteprice,somebodyisgettingtheshaft,eitherthecustomerortheshop,becauseyoudon’tknowwhatyou’regoingtoneed.Ifwetakethemotorapart,wedon’tknowwhetherwe’regoingtoneedpistonsornot.Thatstuff’sallextra.Ithinkthat’swhatmakespeoplefeelcomfortable.Wedon’tgivepeopleatimeline,becauseonceinawhilethingscomeup.…Iusuallyliketodoitwithinayear.”Perkins’right-handmanTimLaehr,whohasbeenwithhim19years,and

part-timerDennisDegner,whohasbeenwithPerkins20years,doalmostalloftheworkthemselves.Theyfarmoutoccasionalupholsteryrepairs,but“wegetsuchgoodcarstostartwith,alotoftimeswedon’thavetodomuchupholsterywork.I’vegotguyoverinOconomowoc,andifweneedapieceputin,hedoesit.Itdoesn’tpayforustoevenhavethesewingmachinetodoit.”Beyondthat,abouttheonlythingthebusinessdoesn’tdoistheheavymachiningonengineblocks.“Oneofmypetpeeves,somanyoftheserestorationshopsareislikeageneral

contractor.Oneguydoesthepaintforthem,oneguydoestheengineforthem,oneguydoestheupholsteryfor‘em,”Perkinssaid.“Timisagreatbodyman…Idoallthepaintandthedetail.Wedoallofour

platinghere.Wedoourphosphating.WedoourInsta-Black.Wedothecad-zinc.Wedoallthepaint,allthebodywork,anywelding.We’veneverhadanybodyeverhelporanythingonthepaint.Everycarthat’severcomeoutofourshop,ifthereispaintonit,I’vepaintedit.Itakeprobablymoreprideinthatthananything.Weneverusebasecoat-clearcoat.Everythingissingle-stage.“That’soneofourlittlethings,ispaint.Tome,60to70percentofa

restorationispaintandbodywork.That’swhereyouspendyourtime.”

Attimes,Perkinsseemsalmostapologeticthathehandles“only”lengthy,high-endBoss429projects.Thenatureofthecars—thoserare,covetedmuscleicons—dictatesthekindofworkthatisrequired,however.AndPerkins’ownfascinationwithmakingcarsappearasoriginalashecanmakethemseemstobeaperfectfitforthecustomerswhoseekhimout.“Theblackonewejustfinished,itdidn’tmatterwhatitcost,theownerdidn’t

wantanycompromiseonanything,”Perkinssaid.[Hesaid]‘Iwantittobethebestone,sothatwhenItakeitsomewhere,Idon’tcarewhojudges,theycan’tfindanythingwrongwithit,otherthanasubjectivecall.’“Withthose,youdon’thavetobeinarush.ThosearethekindIlike.”

CTCAUTORANCHThe‘interstate’salvageyardbearsrust-freeTexasfruit

CTCAutoRanchinDenton,Texas,isoperatedbybrothersDavid(left)andAllenWilliamson.Thepair,alongwiththeirfather,Dale(nowretired),havebeeninthebusiness

ofsellingvintagevehiclessince1985.

ByRonKowalkeSalvageyardsarecommonlylocatedinout-of-the-way,secludedlocations,surroundedbytall,vision-obscuring“beautyfences.”Thatout-of-sight,out-of-mindscenarioworkswellwheretownsfolkdon’treactkindlytohavinga“junk

yard”intheirbackyard.CTCAutoRanchofDenton,Texas,cantaketheoppositeapproach.Highlyvisible,seenbythousandseveryday,thisin-your-facestrategyhasworkedextremelywellforthesalvageyard.

Intheearly1950s,Chevroletproducedasmallnumberofsedandeliverieseachyear.CTCAutoRanchhasatrio(includingthispair)oftheworkhorsesonwheels.Eachisinsolid

condition,butmissingselecttrimand/orglass.

Inoperationsince1992inDenton,theyardislocatedonthewestsideofInterstate35,justnorthofDallas.HavingitsinventoryondisplaytotheconstantstreamofdailyI-35commuters,theyardhasalsogainednoticefrombeingwrittenupinmanyautomotivepublications(includingOldCarsWeekly)andhadcarsfromitsinventoryusedinautomotive-themedrealitytelevisionshows.Sopopularisthissouthernstorageofvintagecarsandtrucks,theyard’sownersevenproduceanannualcalendarshowcasingvehiclesonsitetoactasayear-roundreminder—again,anoffshootofthein-your-faceapproach—oftherust-freeandcompletevintagevehiclesforsale.And,forthosestillunawareoftheyard’sexistence,abrightyellow,elevatedbillboardfrontingtheyardpropertyannouncesitslocation.

OperatedbybrothersDavidandAllenWilliamson,CTCAutoRanchisthesuccessortothebrothers’firstbusinessthat,alongwiththeirfatherDale(nowretired),soldvintagevehiclesinLewisville,Texas(justsouthofDenton).Launchedin1985,DavidWilliamsonrecalled,“Westartedfromnothing.”HavingoutgrowntheLewisvillepropertyby1989,headded,“Wemovedtoourcurrentlocationin1990,andstartedthesalvageoperationin1992.”Currentlyutilizing40acres,CTCAutoRanchhasapproximately4,000

vintagecarsandtrucksinitsinventory.“Theyardislaidoutbymanufacturer,”Williamsonsaid,addingthat20

percentoftheinventoryisavailableforsaleaswholevehiclesonly,withtheremaining80percentofferingparts.“Mostofourwholecars[andtrucks]havetitles,”addedWilliamson,butcautioned,“Wewillnotsellawhole[vehicle]ifnotitleexists.”

This1956Chevrolet3100showsyearsofruggeduse,butcouldstillhavelifeleftinitsomerestoration.

WalkingthespaciousaislesofCTCAutoRanchfindsmanyofthesedividersarepaved.Thismakesajourneythroughthemassive,mildlyhillyyardacomfortableexperience.Notonlyarevehiclesstagedbymanufacturer,asWilliamsonexplained,buttheyalsoaremainlygroupedbymodel.It’saregular

sighttoseeaseriesofBuickRivierasorDodgeCoronetsorFordFairlanesparkedbumpertobumperordoortodoor.ThecoreofCTCAutoRanch’sinventoryispostwar,withthebest

representationbeingthe1950sthrough’70s.Examplesofforeignvehiclesanddomesticindependentmanufacturersexist,butthebulkofinventoryismainstreamDetroitiron.Aselectnumberofmusclecarsdotthelandscape,andWilliamsonsaid,“WehavesomeGMperformanceV-8s,like454s,andwehavePowerglide[transmissions],butnoHemis.”ThelargevolumeofvehicularinventoryisaresultoftheWilliamsonbrothers’

reluctancetoscraptheircarsandtrucks.“Weonlycrushedonce,inthesummerof2012,”Williamsonrecalled.“Wecrushed180carstomakeroomformoreinventory.”Addinginventory,Williamsonstressed,remainsabigpartofthebusiness.“Westillgetcallsonadailybasisforretrievingoldcars.”

The“cat’seye”taillampsandspread-wingreardesignannouncethisChevroletBiscaynetwo-doorsedanasapopular1959model.Itsinteriorhasbeenmodifiedandselecttrimis

missingordamaged,butthecarisverysolid.

Only5,432DodgeCoronetClubSedanswereproducedin1959.Asidefromwindshieldandtrimdamage,thisexampleisrustfreeandcompleteenoughtowarrantrestoration.

Showingbleachedpaintfromexposuretothesun,this1956FordFairlaneVictoriaisinneedofacosmeticupgradeandnewrubbertoreturntotheroad.

Inadditiontothemassiveinventoryofvintagevehicles,CTCAutoRanchalsooffersalargequantityofparts.Williamsonsaidtheyardmaintainsa

computerizedlistingofallavailablevehiclesandparts;itcanbeaccessedonlineatwww.ctcautoranch.com.ForpotentialcustomersunabletotraveltoDenton,Williamsonexplained,“Wedoalotofphonesales.Weshipallovertheworld.”

Notasplentifulastheirdomesticcounterparts,foreigncarsexistinCTCAutoRanch’sinventoryincludingthisuniqueRover2000TCsedan.TheRoverispoweredbyanOHC

four-cylinderenginetoppedwithdualcarburetors.

AMCproductsarewellrepresentedinCTCAutoRanch,includingthis1965RamblerMarlinfastback.This“fish”wasdefinitelyofthesaltwatervariety;rustisevidentarounditsrear

wheelopenings.

Ifacustomerisunabletofindwhatheneedsamongthepartspiles,andsomethingmustberemovedfromavehicle,oneofthreeCTCAutoRanchemployeesmustperformthedisassembly.Forawholevehiclepurchase,Williamsonsaidtheyardcanprovidetheequipmenttoloaditonacustomer’strailer.ToursofCTCAutoRanchcanbearrangedbyappointmentonly.Theyardis

openyearround.HoursofoperationareMondaythroughFriday,8:30a.m.to5:30p.m.(CST).

AfewmusclecarsremaininCTCAutoRanch’sinventory.Oneisthisdamaged1969DodgeCoronetSuperBeehardtop.Thecar’sdrivetrainismissing,butitcouldstillbea

worthwhileproject.

AlargesectionofCTCAutoRanchisdevotedtopickupsandlight-dutytrucks,includingexamplesfrommosteverymanufacturerfromthe1950sthrough’70s,suchasthis’58

FordF-100.

Kaiser’soutputwasminisculeneartheendofitsU.S.productionin1955,makingthis‘54sedanararesurvivoranda“statement”carworthyofrestoration.Itsportsasetof$290

optionalwirewheels.

It’smissingafewkeypartsupfront,butthis1960LincolnPremiereHardtopCoupeisrare.Only1,364wereproduced,andthissurvivorisrustfreeandretainstheexclusivePremiere

badgesonitslowerfrontfenders.

CTC’ssheetmetalinventoryincludesthispairof1937Fordfenders.

ThecenterportionofCTCAutoRanchhasalargecollectionofrust-freeparts,includingavarietyoffendersfrontedbya’56Buick“porthole”example.

Appearingasifitweresuckerpunchedinitsdriver’ssideheadlamp,this1959FordRancheroCustompickupisinneedofconsiderablerestorationtoreturntotheroad.Fordbuilt14,169RancheroCustomsin’59,andmostsawharduseasworktrucksanddidnot

survive.

Lookingverysolid,althoughmissingafewkeyparts,thisformerlyfactoryairconditioned1955ChryslerNewYorkerDeluxetwo-doorhardtopcouldserveasagreatpartscartoa

rustyC-300,ifnotbecominganambitiousrestorationprojectitself.

Otherthantireissues,this1964ChryslerNewportTown&Countryhardtopstationwagonappearscompleteenoughtobedrivenoutoftheyard.Only6,761ofthismodelwere

produced,inbothsix-andnine-passengerforms.

Theinteriorhasbeentornapartinthis1956PlymouthBelvedereSportCoupe,butit’sotherwisenearcompletedowntoasetofnon-originalhubcapsand“ForwardLook”

medallionsonitsrearquarterpanels.

Texashasalonghistoryinvolvingoutlawsandguns,soit’sonlyappropriatethatthisbullet-riddled“bathtub”Nashsedanbecomeoneofthelandmarksinthelargeyard.

Itssofttopisintatters,butthebodyofthis1966PontiacBonnevilleconvertibleisrustfreeandretainsitsfenderskirts.Theragtopismissingitsstainlesssteellowersidetrim,butis

otherwisecomplete.

Late-1950sImperialcoupesareveryrare,andspottinganexampleinasalvageyardtodayisevenrarer.Thissolidunitwouldrequireasignificantamountofworkbeforeitcould

returntotheroad,butthefab’50sgreenpaintschemewouldmakeitworthyoftheeffort.

COLORADOYARDTHE‘HOMEOFGLAMOROUSBODIES’

WollerAutoPartshas7,000vehiclestochoosefrom

StoryandphotosbyRonKowalkeWhenthingsgoright,ourluckisoftenattributedtoplanetsbeinginalignment.Now,I’mnotsuperstitious,nordoIpretendtoknowmuchaboutastronomyotherthancertainphasesofthemooneffectoceantidelevelsandwerewolves.But,asluckwouldhaveit,planetsdefinitelyalignedformelastfallonatriptoColorado.Inlessthan48hours,IvisitedthreecollectionsofsalvagecarsthatrivaledthebestyardsI’veeverseen.

Another1959ElCaminointheyardhasadonatedfrontclipfromanotherChevy,anditsrearbumperislyinginthebed.Thisexample,too,hasrestorationpotential.

WollerAutoPartsinLamar,Colo.istuckedintothesoutheastcornerofthestate.Thewordingonitsbusinesscardaloneisenticementenoughtoplanavisit:“WollerAutoParts,Inc.—HomeofBeautifulWrecks&GlamorousBodies.”

MuchtoseeAmongthelargestsalvageyardsinthecountry,WollerAutoPartshasan

inventoryofapproximtely7,000vehicles,accordingtoyardmanagerAndyWoller.Inventorymainlyspanstheyears1955to2000,butafewcarsandtrucksfromthe1930sand’40scontinuetopopulatetherows.Thatmassofmetalisspreadover65acres,andtheyard’slayoutisextremelyuserfriendly:flatterrain,wideandgroomedaisles,vehiclesarrangedinneatrowsandmostlygroupedbymanufacturer.Thisyardalsospecializesincompleteornear-completevehiclesforsale,fromwhichpartsremovalisforbidden.WheneverIvisitasalvageyard,I’mtryingto“seeitall”togetabalanced

viewofwhatinventoryisavailable.Ispentmorethantwohourswalking(swiftly)amongtherows,andIsawfewerthanhalfofthevintagevehiclesthatarepresentatWoller’s.Acustomerwhoislookingforaspecificpartorcarwillbedirectedimmediatelytotheareahostingthatpart/vehicle,whichdefinitelysavestime.Andthat’stheruleatWoller’syard.Allcustomersarechaperoned,andthatincludedme.

The“cat’seyes”taillampsmarkthisChevyElCaminoasadesirablefirst-year1959model.Thedamagedquarterpaneldoesnothingtodiminishtherestorationpotentialofthis

car/pickupmergermodelatWollerAutoParts.

AmongtheChevroletmusclecarsintheyardisthis1964ImpalaSShardtop.Itshoodismissingandthedecklidispunchedin,butthecarisotherwisestraight.

Fromaconditionstandpoint,this1955BuickCenturyRivierahardtopranksinthe“aboveandbeyond”categoryofwhatisusuallyfoundinsalvageyards.Thisisoneofmany

vehiclesinWoller’syardthatdeservesanewlife.

SimilarinfrontalappearancetothehighlysoughtperformanceRebelmodel,this1957RamblerSupersedanhassufferedonlyminorcosmeticdamageandiscompletedowntoitshubcaps.Withonly16,320produced,thisRamblerwouldmakeagreatsurvivor-class

driver.

AyoungmannamedKevinWilsonactedasmytourguide.Wilsonhadadecentgraspoftheinventory—agoodportionofwhichlikelyarrivedbeforehewasborn.HepointedoutinterestingcarsandtrucksandwaspatientwhileItriedtoworkaroundthelongsunriseshadowswhilephotographingvehicles.Wilsonsaidhehasaspirationsofsomedaybeingarestorerofvintagecars,andIcouldn’timagineabewtterstarttoachievinghiscareergoalthanworkingatWollerAutoParts.

DestinationLamarSome42yearsago,accordingtoAndyWoller,anotheryoungmanwho

originallyhailedfromMichiganwasponderinghisfutureashisstintintheArmywasnearinganend.ThatwasDonWoller,Andy’sfather.HehadcometoLamartovisitamilitarybuddyandenjoyedtheareasomuchhedecidedtosettlethereandstartasalvageyardbusiness.It’sabusinessthatnowspanstwogenerationsoftheWollerfamily,asDonandhiswifeGloriaowntheLamaryardthatismanagedbytheirsonAndy,whileanotherson,Jeff,ownsasalvageyardsouthofLamarthathasaninventoryofmoremodernvehicles.

Afewwrinklesupfrontandasaggingheadlinerhardlydetractfromtheoverallsolidappearanceofthis1968PlymouthBarracudafastback.Itslarge“greenhouse”rearglassis

alsointact.

DonandGloriawereoutoftownthedayIvisited,soAndyWollerandKevinWilsonprovidedallthedetailsofwhatWollerAutoPartsofferstovintagevehicleenthusiasts.

Beyondthesupervisionofcustomerswhileintheyard,Wollersaidemployeespullallpartstobepurchased,althoughregularcustomersmaygetsomelatitudeonthatrule.Headdedthatpartscanbeshipped,ifacustomerneedsthatservice.Also,muchoftheinventoryacquiredinthepastfewyearsisloggedonacomputer,socustomerswhocoldcalllookingforaparticularvehicleorpartcangetspecificanswers.Whenaskedabouttherecallofveteraninventorythat’sbeenresidingintheyardlongterm,Wollerreplied,“Ihaveagoodmemoryofwhat’sintheyard.”Inadditiontowholecarsandpartscars,theyardofferslotsofrandomparts

forsale.Amongtheseitems,Wollerspecificallylistedalternators,starters,windshieldsandaxles.Headdedthattherearealsomanyloosepartsstoredinthetrunksofthevehiclesintheyard.

BowtiemuscleWithinventorythatspansbacktothe1950s,Ihadtoinquireaboutthe

availablilityofperformancecarsandparts.“There’snotmuch[remaining]inFordorChrysler,butwehavequiteabitofChevy[carsandparts],”Wolleranswered.SomeofthatChevy-heavydisparitycanbeexplainedinwhatWollersaidis

stillbeingdiscoveredaroundLamarandaddedtotheyard.“WefoundtwoSS-396carsinthewoodsjusttheotherday.”Helaterrecalled,“Mybrotherfounda1967ChevelleSS-396inagarageinLamar.Anoldladyhadit.”

Itwasasurprisetofindthis1958Packardhardtop(aboveandbelow)incompletecondition,althoughithasrustinitslowerbodypanelsandsignificantglassdamage.Only675hardtopswereproducedinPackard’sfinalyearofproductionin’58,makingthisa

pieceofhistoryworthyofrestoration.

Whilegroupingofmanfacturerswithinrowsiscommonintheyard,thereareareaswherespecificmodelsarefoundtogether,suchasthistrioof1958Chevroletstationwagons.Nearbyisanareawherealargenumberof1955-’59Chevysofvariousbodystylesare

stackedtwohighinrowstoconservespace.

WollerAutoPartsemployeeKevinWilsonstandsbyadamaged1968DodgeChargerbodyshellthatwasstillavailable.

TheCustomline-stylestraightsidetrimonthis1955FordCountrySedanmarksthisasasix-passengerstationwagon.Atsomepoint,itwasconvertedforuseasanambulanceas

thebarelyvisible“AMBULANCE”letteringonitssidesattests.It’sstraightandsolid.

Crewcabpickupsareacommonbodystyletoday,butwererareintheearly1960s.Theywereusuallyproducedformilitaryuseandfleetorders.Thebedofthis1962-’64D-100six-

passengerpickupisdamaged,butitscabandchassishaverestorationpotential.

Wollersaidatonepointtheyardcontainedasmanyas20ofwhathelooselytermed“GeneralLee”DodgeChargersfrom1968to’70.MostofthoseweresoldyearsagotoonebuyerfromWisconsin.NotforgettingtheneedsoftheBlueOvalenthusiasts,Wollersaidhealso

recentlygotaleadona“two-seaterFordThunderbird”thatwasdiscoveredlocallyinsideabarnthathadcollapsed.HeaddedthathisfatherownsapairofChevroletsinhispersonalcollectionofvehiclesthatwerealsorescuedfromacollapsedbarn.Oneisa1966SSconvertibleandtheothera’17pickup.

Buyingcars

Titlesexistformanyofthevehiclesininventory,andforthosewithout,theycanbesoldonabillofsale.Eventually,thevehiclesininventorywillallbeproppedupoffthegroundonwheelstands.RustdoesnotappeartobeanissueinthedryclimateofsoutheastColorado,butelevatingthecarsandtrucksaffordsanextrameasureofpreservation.

Whilenowherenearasprevalentaspostwarvehicles,thereareinterestingprewarcarsandtrucksinWoller’sinventory.This1939FordStandardTudorsedanismissingsomepartsandhasagougeinitsroof,butitretainsitsflatheadV-8anddriver’ssidespotlight.

WollerAutoPartsisopenyear-round,withtheexceptionoftheweekbetweenChristmasandNewYear’sDay.RegularhoursofoperationareMondaythroughFriday,8a.m.to5p.m.(MountainTime).TherearenoSaturdayorSundayhours.Grouptourscanbearrangedbyloggingontowww.classiccarauto.comforanappointment.

Tocontacttheyard,phonetollfree800-825-0210or719-336-2108,usee-mailaddressdgwoller@hotmail.comorpostalmailingaddress:WollerAutoParts,8227RoadSS,Lamar,CO81052.

Asolid1951KaiserSpecialsedanthathasbeenlootedofmuchofitstrim.

PLATEPERFECTIONTheartoflicenseplaterestoration

By‘Rotten’RodneyBaumanWhileIdon’tnecessarilyrecalltheexactstatistic,it’sbeensaidthattheaverageworker-beechangescareercoursesseventimesinhisorherlifetime.AlthoughIcouldhavebeenadoctor,alawyerorafamousunderwearmodel,I’vemadeacareerofstraighteningbodypartsofoldcars.Earlyon,Iwaswarnedofthe“occupationalhazards,”sothetrickknee,junkrotatorcuffs,tenniselbows,carpaltunnelsandtherecentdoubleherniaarenobody’sfaultbutmyown.Nowinmymid-50s,Ifindmyselfstillswingin’heavyhammers,andjustbetweenyouandme,Icouldreallyuseabreak.Atypicalworkdayhereatourshopwouldlikelyincluderollingaroundona

concretefloorwhileabsorbingallthenot-so-goodvibrationsfrompneumatictools,suchasaDA(dual-action)sander,orworse.Inthebodyandpaintdepartments,evenonhotdays,arespiratorisamustforsurvival.Butthestrap-ondevicewillelevatethehumanbody’soperatingtemperatureasrecycledbreathhasnegativeeffectsofitsown.

Itwasrightaround3p.m.ononeofthosetypicalworkdays,duringpeaksummerheat,whenIhadtowalkaway.Ipulledoffmyrespirator,elbowbracesandsweat-filledlatexgloves.ThenIgrabbedacoldbeverage,satdownonastoolandletmymacular-degenerativeeyeswanderaroundtheshopwhereallmannerofunfinishedprojectsbegantoconfrontandallbutganguponmyguilt.So,Itooka’63-issueCalifornialicenseplateoffthewallandgottothinkin’.

PerhapsIcouldstraightenitupalittle.Iwouldn’tneedarespiratororthoseuncomfortableelbowbracesforsuchasmalljob,soitseemedlikeanOKideaatthetime.Iproceededtocleartheweldingtable,mademyselfaplacetowork,andaboutanhourlater,theprogresswasquiteencouraging.Thattinybitofsuccessgotmetothinkin’somemore.I’veneverhadany

desiretorestorelicenseplatesbefore,butthesedays,it’sgoodtohaveextra

tricksinthebag.So,aslongaswe’realltogetherhere,I’llshowyouhowit’sdone.

ResourcesMcPeakPainting&Pinstriping1237W.LaCadenaDriveRiverside,CA92501951-683-1292

Evercoatwww.evercoat.com

PPGIndustrieswww.ppg.com

Here’soursubjectlicenseplateonthetable.Atthisstage,agoodamountoftheroughoutworkisdone.Alonghorizontalfoldandthelargerdingsarealreadysmoothed.Sofar,ourspecific-purposelicenseplaterestorationtoolshavebeenmadefromobjectsfoundwithin

reachandtheassortmentwillgrowaswego.

Withasectionofsteelchanneltoserveasananvil,areascanbeaccuratelysteeredaroundsothatcertainareaswon’tbeflattened,suchasthetinyribaroundtheedgeoftheplate.Thisparticularhammerisanantique,anditssquare-facedendisobviouslywell-

suitedtothelargerareasbetweencharacters.

I’veneverthoughtmuchofthisAllenwrench,butasalicenseplatetool,itprovedtobeinvaluable.Coincidentally,theshapeofitshandleevenbearsastrongresemblancetothe

shapebetweenareasofthelicenseplatewherecharactersareclosetogether.

Thetimingwasrightforthistool.Whilegrillingoutthenightbefore,InoticedthatweneededanewBBQbrush.Thehandlefromtheoldonemadeaverycooltool,especially

forworkingtheinsidesectionsoftheletter“H.”

Nowwesaveoldpaintbrushhandlesforlicenseplaterestoration.Ourcollectionisindeedgrowingaswego.Tothispoint,therawmaterialsneededforourtoolsseemtobeall

aroundus,andwe’renothuntinglongtofindthem.

Here’sanothergoodexampleofhowspecific-purposetoolscanbefashionedfromordinaryhouseholditems.Asitturnsout,pencilscantakeatapping.Thisparticularpencil

isaperfectmatchfortheroundedendsofthecharacters.

Woodenpaintstickshaveproventobethemostversatileofourtoolssofar.Whengluedtogethertothedesiredthicknesses,they’resurprisinglystrongandtheycanbeeasily

trimmedandsandedtomostanyneededlengthorshape.

Atthisstage,there’sbeensometimeinvested.Instincttellsmethatourtestplatewillstillrequireafinefinessingwithfillerbetweenbeadblastingandprimingsteps.

Nottoobad,eh?Carefullyguidedglassbeadshavegentlyremovedtheoldpaintwithoutwarpingthethin,sheetsteelplate.Strappedtotherightarm,asimplegroundbracelet

ensuresagainststatic-electricshock.

Backtowardthebeginning:Thethingthatfirstattractedyourstrulytolicenseplaterestorationwascomfort.HereI’vesetupasterilizedworkstationforthenecessarybitof

fillerwork.Withtheplatetapedtothetable,we’rereadytogo.

Sometimes,there’safinelinebetween“readytogo”and“readytogobackward.”IwishIhadnoticedthistinycrackearlier.

Withtheplatecutfreeonceagain,it’sobvioustherearetwocracksinneedofattention.Ofcourse,Iconsideredcheating.J-BWeldsandsfine,anditmightevenwork,butIcouldn’t

taketheshortcut—notthistime.

Sincewehadthemanyway,acouplechunksofbrasswillmakeagoodbackupforMIGweldingthethin,crackedsteel.Theweldswon’tattachthemselvestobrass,sothisounce

ofpreventionshouldhelptoensurethatwewon’tburnthrough.

SonowthatI’vesetitup,I’vecalledinaringer:ourdesignatedwelder,“Mrs.Rotten.”Shewon’truintheplatelikeIprobablywould.

Followingwelding,alittlegrindingandasecondridethroughtheol’beadblastingcabinethaveputtheprojectbackontrack.Hereonthebenchareafewtoolsandmaterialsthat

I’veanticipatedmightbeneededfortheupcomingfillerwork.

Forthefill,we’reusingEvercoat’sQuantum1.Withitsthinviscosityandchoicesofcatalysts,itseemslikeanaturalforthisjob.I’veoptedtousetheslowcatalyst,whichwillallowthetimeneededtobrushiton.Sure,thebrushwillbejunk,butthehandlecanbe

reusedasafuturelicenseplatetool.

BeforeQuantum1iscured,itwillcontinuetoflow,sothebrushstrokeswillself-level.Onceapplied,butstillliquid,maskingcanbeeasilyremoved.Themaskingisjustan

optiontoensurethatfillerwon’ttravelbeyondwhereit’sneeded.Therewillbeplentyofsandingtodoasitis.

WhenIspiedthisDynabradedetailsanderattheSEMAShow,IknewI’dhavetohaveone,eventhoughIwouldn’tneediteveryday.Forthisspecialoccasion,it’satime-saving

advantage,asourcuredQuantum1respondswellto120-gritforthefirstroundofsanding.

Likemanybodyguys,Iliketomodifysandingblocksforthejobathand.ThisonewascutthiswayforblockingbetweenrevealsatthetailendofanoldCadillacwerestored.Thatwasyearsago,butI’llbedippedifitisn’tcominginhandyonceagainforthenumber“8.”

Sureenough,afterinitialsanding,therearedetailstoniggleover,asisusuallythecasewithlargerfillerapplications.Onceagain,we’vepoppedthelidfromthegalloncanofQuantum1.Thistime,however,alittledab’lldoit.Asbefore,maskingtapeisusedto

directfilleronlywhereit’sneeded.

Asthefinalbitoffillerisblendedin,we’rejustaboutreadyforprimetime.

Oh,déjàvu.Hereagain,inthissituation,we’reafter“highbuild”andourprimerofchoicewillfunctionasourfinalfiller.Whosaysweneedaspraygun?Ittakesacouplewhilesto

cleanoneproperly,solet’scheatalittle.

Granted,we’velostalittlecharacterdefinition,butknowingso,we’llattempttosharpenthingsupduringfinalblock-sanding.WiththeexceptionoftheDyanabradedetailsander,thetoolsusedforfinalpaintprepwillbeprettymuchthesameaswe’vealreadyused.

Atthispoint,it’ssafetosaythatwe’reinthefinalstagesofpreparationforpaint.Withtheadvantageofoptionalreduction,ourprimerofchoicedoublesasanon-sandingsealer,so

320-gritshouldbeanacceptablestoppingpoint.It’sjustalicenseplate,right?

Here,thenon-sandingsealerisonandsogoesourfirstoftwocolorcoatsofsingle-stage,acrylicurethaneblackfromPPG.

Aswenearcompletionofourlicenseplaterestorationproject,we’redowntotheshortstrokes.Knowingmyownlimitations,I’vecalledinasecondringer,ourdesignatedsign

painter.

We’vepassedtheletteringchoresalongtoMcPeakPainting&Pinstriping.McPeakalsorestoresoldlicenseplatesfromstarttofinish.Afterallwe’vebeenthrough,we’llkeepthat

inmindfornexttime.

Havingrestoredalicenseplate,wecameawaywithnewrespectfortheprofessionals.Thistypeofworktakesalotoftime,withanextrahelpingofpatiencethrowninforgood

measure.Aswithanyotherauto-restorativeprocess,speedcomeswithexperience.We’vegainedalittleofboth.There’sanothertrickforthebag.

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StartingfreshwithKanterpartsKanterAutoProductsisalreadyago-toplaceforchassiscomponents,and

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Newsteelfor1940sFords

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DAputsnewspinonpolishingMeguiar’sDAPowerSystemeasesmachinepolishingbymakingiteasy,

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information

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HAULINGYOURCARTHERIGHTWAY

Thetoolsandtricksbehindasafehaulingexperience

ByWilliamC.“Bill”Anderson,P.E.Bringupthesubjectoftraileringavehicleincollectorcarcirclesandyouaresuretoprovokeananimateddiscussion,ifnotanoutrightargument.Regardless,haulingacarisoftennecessaryevenifitinvolvesarestoredcarthatisalwaysdriventoshows.Forexample,bringingtheyet-to-be-resurrectedjewelhomeforthefirsttimeorwhen,heavenforbid,itbreaksdownandcannoteasilyberepaired.I’vebeenhaulingcarsformanyyearsbothbeforeandafterrestoration.

Fortunately,Ihaveencounterednohaulingproblems.That’strueformostothersaswell.However,overtheyears,I’veheardmanystoriesaboutthosewhowerenotasfortunate.Perhapsit’smyengineeringnature,butwhenIstartedhaulingcars,Isought

adviceonproperproceduresandfoundlittledefinitivehelp.Astheyearsprogressed,mysearchhascontinued.Nomanualhasbeenfound.Everyoneseemstoemploywaysthathavebeenpassedonfromothers.

TiedownringusedwithVersaTietrack.

So,IthoughtI’dassembleasmallmanualtoguidethosewhowanttomaximizetheirchancesforsuccesswhenhaulingacar.Tothatend,I’veengagedtheassistanceofthefolksatMac’sCustomTieDownsinSagle,Idaho;www.macscustomtiedowns.com.Mac’swasalsocourteousenoughtosupplyalltheimagesusedinthiscolumn.Forthiscolumn,I’llskipsuchessentialpointsasmakingsurethatthetow

vehicleissizedfortheloadbeinghauled,thataproperlysizedhitchisemployedandthatthetrailerisproperlyconnectedtothetowvehicle.Instead,thefocuswillbeontyingthecartothetrailer.Therearefourwaystosecureacartothetrailer:(1)connectingthetiedown

strapstotheaxles;(2)connectingthetiedownstrapstothefactorytiedownlocations;(3)connectingthetiedownstrapsthroughthewheels;and,(4)securingthewheelsbywheelnets.

Tiedowns

Thestandardtiedownstrapiscomprisedoftwo,two-inch-widestrapswithintegralsnaphooksconnectedbyaratchetfastener.Tiedownsusetwodifferentratingsandit’simportanttounderstandthedifference.Breakingstrength(MBS)isthemostcommonrating.Itindicatesthemaximumsafeloadforastrapunderastraight,staticpull.ThemoreimportantratingistheWorkingLoadLimit(WLL),whichisone-thirdoftheMBS.TheWLListheforcethestrapcanreliablyholdunderdynamicconditions,suchastravelingalongabumpyroad,braking,etc.TherecommendedstrapWLLforhaulingmostcarsis3,330lbs.(10,000lbs.MBS).Toensurethattheratingsadvertisedareobtained,it’srecommendedthattiedownsbepurchasedfromaqualitysupplier.

TypicalbackingplateforuseininstallingrecessedD-rings.

StandardrecessedD-ring.

Recessed360-degreeSwivelD-ring.

Mac’sVersaTietrack,surface-mountversion.

StandardA-trackwithatrackconnector.

Correctlyconnectingthestrapsisessentialtoobtaintheadvertisedrating.Thisisaccomplishedbywrappingtwofullturnsofthestraptotheratchetwindingshaft.

TrailerattachmentpointsTherearetwoprimarytrailerattachmentmethods—D-ringsortracks.D-

ringsarethemostcommonandareavailableasarecessedD-Ringratedat5,000lbs.ortherecessed360-degreeswivelD-ringratedat6,000lbs.Atracksystemismoreexpensive,butitallowschangingtheconnectionpointsforvehiclesofdifferentlengthsusingspecialfittingsthatinsertintothetrack,providedthevehicle’strack(width)dimensionsaresimilar.BothMac’sVersaTietrackandthestandardA-Trackareratedat3,000lbs.perconnection.TheVersaTietrackcanberecessedinthetrailerfloororsurfacemounted,whiletheA-Trackissurfacemountedonly.Tracksystemsalsoallowforadjustableplacementofidlers.Idlersareusedwithtracksystemstokeepstrapsclearoflow-hangingcomponentssuchasairdams,diffusers,fenderedges,etc.

Somewheeldesignspermitthrough-wheelconnections.Theaxlestrapshouldbecoveredwithawearsleeveandafleecesleevetoprotectthewheelfinish.Note:(1)howtheratchetstrapisinastraightlinebetweentheaxlestrapandtheD-ring,(2)thehooksopendown,

and(3)theextraratchetstrapisneatlytiedupwithastrapwrap.

TheloadratingsoftheattachmentpointscanonlybeobtainediftheD-ringortrackisthroughboltedusingGrade5or8fasteners.Forwooddecktrailers,it’salsoimportanttousesteelbackingplatesunderthetrailerfloor.D-ringsareattachedwithfourboltsperringandtracksareboltedeverysixinches.

Crossedstrapsvs.straightstrapsSomepeopleconnectthestrapsfromonesideofthecartotheattachment

pointontheoppositesideofthetrailer—crossedstraps.Othersconnectthestrapfromthecartothetrailerattachmentpointonthesamesideofthetrailer—straightstraps.Whichmethodisbesthaslongbeendebated.Manyoldproshavecrossedstrapsforyearsbelievingthatthismethodwillpreventthecarfromshiftingfromside-to-sideasittravelsinthetrailer.Thisthinkingiscorrectifthereisnocollision.However,inafront-endcollisiontherearstrapsareseverelystressedandcouldfailbecauseangledstrapshavelessstrengthinthedirectionoftravelthanstrapsinastraightlineandparallelwiththedirectionoftravel.Inthisinstance,thecarbeinghauledwouldcomelooseinthetraileranddamageitaswellasexacerbatethecollisioneffects.Crossedstrapscanalsobecomepinchedwhenattachedtothesuspension—particularlyatthefront—andcutthewebbing.Straightstrapspullfront-to-rear,andtherefore,theirmaximumstrengthis

appliedinthedirectionoftravel.Theywillalsokeepacarinplaceundernormalroadconditions.Currentprofessionalconsensusisthatstraightstrapsarebest.Regardlessofthemethodchosen,it’simportantthatallstrapsbesecurelyand

equallytightenedtoobtainthemaximumholdingstrength.Clothstrapswillusuallyloosenalittleafterafewmilesofhauling.After10-20milesontheroad,IalwaysstopandtightenallthestrapsandIcheckthemateveryfuelstop.

TheJ-Hookisthesimplestconnectortousewithfactoryconnectionpoints.

TheT-HookconnectorismoresecurethanaJ-Hookiftheframewillaccommodateit.

TheR-Hookcanbeusedwithsomefactoryconnectionpoints.

SummaryofthegearTheabovepointsarefundamentaltoproperlysecuringavehicletothetrailer.

Ire-emphasizetheimportanceofusingallqualityproducts;thisisnottheplacetosaveafewdollars.Thenextpartcoverstheadvantages,disadvantagesandhow-torecommendationsforeachofthefourwaystoconnectacartoatrailer.

Securingcarbytheaxles

HowtodoitUsequalityaxlestrapswithprotectivewearsleeves.Thesleeveshouldrunthe

fulllengthofthestraptopreventitfromshiftingfromthesuspensionduringthehaul.Onpolishedorchromedaxles,apaddedfleecesleeveoverthewearsleevewillhelpprotectthefinish.Also,keepingboththestrapsandthesuspensioncleanwillhelppreservethefinishandthestraplife.Wrapthestrapsaroundtheaxlesorlowersuspensionarms.Avoidsharpedges

andburrsinthemetalwhenthestrapisalignedwiththetrailerattachmentpoint

becausethesecaneasilycutthestrapsduringthemanycyclesofmovementthatoccurduringatypicaltrip.Also,donotwrapthestrapsoverbrakelinesorotheritemsthatmightgetcrushedwhentheloadisapplied.Connecttheaxlestraptothefreestrapofthetiedownandtheratchetendof

thetiedowntothetrailerattachmentpoint.Theninsertthefreeendintheratchetaxleandtightentwofullturns.Iftheaxlestraphasbeenproperlylocated,theratchetstrapwillpullmostlystraightforwardorrearwardwithabitofoutwardangle(approximately15degrees)oneach.Makesurethecarispositionedsothattheratchetstrapdoesnotcontactanybodypartstopreventdamage.Forcarsthatarelow,anidlerconnectedtothefloorisusedtopullthestraptothefloorlevelbeforeproceedingtothetrailerattachmentpoint.

AdvantagesMostvehicleshaveeasilyaccessibleandstrongpointssuchassolidaxlesor

A-arms.Itisdifficulttodamageshocksealsandaffectspringrateswiththismethod.

DisadvantagesYoumustgetonthetrailerfloorandreachdeepunderthecartomakethe

necessaryconnections.

Securingcarusingfactorylocations

HowtodoitMostcarshaveholesintheframethatweredesignedinbythemanufacturer

toattach“shippinghooks.”Althoughthispracticeisbeingabandonedforsomenewcarstoavoiddamagetomodernsuspensions,thereareplentyofoldervehiclesthatcanstillbetransportedsafelyinthisway.Therearethreetypesofshippinghooks:J-hooks,T-hooksandR-hooks.J-hookswillworkinframeholesabitlargerthanfive-eighthsinch.Theyarestout,butthesuspensionmustremaincompressedtopreventthehooksfromfallingoutwhendrivingover

potholes.T-hooksuseaslot,roughlythree-quartersofaninchbyone-and-one-halfinches,inwhichtheyrotatetolock,preventingthehookfromcominglooseascanmoreeasilyhappenwithaJ-hook.R-hookscanbeusedonsomeforeigncarsbutnotonAmericancars.Strapscanbesewndirectlytothehooksorthefreeendofastandardratchetstrapcanconnecttothelooponthehook.

AdvantagesWiththerighthooks,hookupissimple.

DisadvantagesThebiggestdisadvantageofusinghooksintheframeisthatifthestraps

loosenalittle,thehooks,particularlyJ-hooks,candisengagewhentravelingoverbigbumps.Compressingthesuspensionforlongperiodsoftimecanalsocompromiseshocksealsandchangespringrates

Securingcarthroughthewheel

HowtodoitUseaspecificallylengthenedaxlestrapcoveredinbothafull-lengthwear

sleeveandaremovablepaddedfleecesleeveandruntheaxlestrapthroughthewheelopeningclosesttothetiedownpoint.Installtheratchettiedown-through-the-wheelstraptothetrailerfasteningpointseitherinlinewithorslightlyoutboardofthewheels.

Whenconnectingtosuspensioncomponents,avoidsharpedgesandstayclearofbrakeandfuellines.

AdvantagesWiththecorrectaxlestraps,connectionsareeasytomake.Excellentstrap

geometrytypicallyresults.

DisadvantagesThismethodcannotbeusedwithsolid-center,stamped-steel,wire-spokeor

alloywheelswithnarrowopenings.Unlesstheaxlestrapfleececoversandwheelsareclean,thewheelfinishcanbedamaged.

Securingcarusingwheelnets

Howtodoit

Thismethodrequiresspecialstrapassembliesthataremountedoverthetopofthetire.Thesewheelnetsmustbesizedforthetiresonthecarbeinghauled.Forpropergeometry,tiedownpointsmustbelocateddirectlyinfrontofandbehindeachwheel.Thismethodisbestusedwiththetracksystem.However,ifcarsofthesamewheelbaseorthesamecarisalwayshauled,D-ringattachmentscanbeused.Forthefronttires,connectthewheelnetaboutthreetofourinchesbehindthe

rearmostpartofthetire,thenupandoverthetire,downtoanidlerjustinfrontoftheforemostpartofthetire,makingthenetpullmostlystraightdown,butalittleforeandaft.Fromthere,thestrapturns90degreesusinganidlerandrunsalongthefloortotheratchetandD-ringinfrontofthecar.Ifthereissufficientroom,theratchetstrapcanbeconnectedatthefrontofthetireinsteadofusinganidler.Theprocedureisreversedforthereartires.

AdvantagesWheelnetsprovidethelowestpotentialfordamagetothecarbeinghauled

andcansecurecarsthatarelow.Thesystemisthestrongestavailable.

DisadvantagesWheelsnetsarebestusedwithatrailertracksystem,whichisexpensive.D-

ringscanbeused,butthreearerequiredateachwheellocation.Correctlypositioningthewheelnetcansometimesbedifficultifwheelclearanceislimited.

SummaryRegardlessofthemethodchosen,besuretogetatleasttwofullturnsofthe

ratchetstraponthemandrel(roller)oftheratchet.Withless,vibrationcancauseatightstraptoslowlyloosen.Also,checkstraptensionafterafewmilesandroutinelythroughoutthetripduringfuelstops.Allsystemsofconnectingacartoatrailercanprovidesafe,securehaulingif:

•TheD-ringsortracksystemareproperlymountedtothetrailerfloorusingthrough-boltconnections;

Thelatestmethodofsecuringacartoatrailer.Wheelnetsarecustomsizedtofitthetires.Notethegeometryoftheconnectionpoints—atthefrontofthetire,theidlerloopatthe

rearandtheratchet—toprovideasecureconnection.

•Thecorrectstrapsandconnectionsspecificallyintendedforthemethodemployedareused;and,•Qualitystrapswiththecorrectstrengthratingsareused.Axleandratchetstrapswearoutwithage.So,don’tbeafraidtoreplacethese

afterafewyearsofuse.Thecostofnewstrapsissmallcomparedtowhattheysecure.ThankstoMac’sCustomTieDowns(www.macscustomtiedowns.com)for

supplyingtheexpertiseandthephotosusedinthistwo-partarticle.

WilliamC.“Bill”Anderson,P.E.,hasbeeninvolvedwiththeautomotivehobbyformorethan30years.ThroughAndersonAutomotiveEnterprises—www.andersonautomotiveenterprises.com—herestoresandappraisescars.

BRINGINGHOMEA‘BARNFIND’Tipstopreparinga‘barnfind’projectvehiclefortheroad

Whilemanyofusintheoldcarhobbydreamofstumblingacrossadustybutotherwiseall-originalvehicleinabarn,it’saveryrareoccurrence.Thatisnottosaythatitdoesn’t

happen.

BySteveTurchetAquestionthatmanyvintagevehicleownersareoftenaskedabouttheirvehicles(besides“isithardtofindpartsfor?”and“whatisitworth?”)iswheretheyfoundit.Asmostenthusiastsknow,thegeneralpublicusuallyassumesthatmostoldcarswereboughtatatelevisedauction.However,thoseofusinthehobby

oftenhavemuchmoreinterestingtalestotellabouthowandwhereweacquiredourvehicles,alongwithamusingoradventurousstoriesabouthowwegotourtreasureshome.Whilesomecollectorsdobuyvehiclesfromauctions,manyvintagevehicles

comedirectlyfromprivatesources.Webecomeawareofthemthroughclassifiedadsinthismagazineorotherpublications,bywordofmouthandoneBayorotherInternetsites.Sometimes,wesimplyspotavehicleinsomeone’sbarnoroutinafield,oftenwhenwe’renotlookingforone.Thesearegenericallycalled“barnfinds.”Justaboutanybarnfindisabletobetransportedinatrailer,andmanyare

towable,whileafewcanactuallybedrivenhome.However,sometimeswhatistowableor“trailerable”(andmaybeshouldbe)istransformedintodrivable.

AfterDiscoveringTheVehicle:LoadingItTheadventureusuallybeginsafterthevehiclehasbeenpurchased.Inmany

cases,thevehicle’snewownerhasbeentoldbythefarmer/rancher/miner/logger,“Shewasrunnin’whenweparkedher20yearsago.”Whatsometimeshappensisthenewownerdecidesthatinsteadofrentingorborrowingatowbarortrailer,theyaregoingtodrivethevehiclehome.Ihavedonethismanytimes,ofteninthedesertorbush,andusuallybecauseIhadtobecauseIlackedtheequipmenttotrailerortowavehicleorthefundstohaveittrailedortowed.However,formanypeople,there’sreallynonecessitytotrytodrivehomeabarnfind,butthere’susuallynonecessitytoclimbamountain,either.Whileeverysituationhasbeenalittledifferent,therearealsosimilarities,

especiallyinthestoriesofotherswho’vedrivenbarnfindshome,ortried.Thesamemistakesareoftenmadeandalotoftimeisoftenwastedbynotdoingthingsinalogicalorderwhenitcomestoinspectingabarnfind,gettingitstartedandmakingitmobile.Insomecases,avehiclesimplycan’tbedriven—orshouldn’tbe—andthesooneronelearnsthis(preferablyonthesamedayonemakesthepurchase),thelesstimewillbewastedtryingtodotheimpossible.

Forexample,aguyoncetoldmehespentanentiredaydismountingall10wheelsofabarnfindM35militaryvehicle,haulingthemtwoatatimeinhisSUVtothenearesttowntoairthemup,onlytodiscoveratsunsetthatthetruck’senginewasseized.Someoneelsetoldmeofadayspentfiringupanold4x4truckonlytodiscoveritwasmissingitstransfercase.Thereasonwhyembarrassmentsliketheseoccurisbecausepeopledon’ttake

thetimetothoroughlycheckoutavehiclebeforetheydecidetheycoulddriveithome.Usually,thevehicle’sformerownerwastellingthetruthandthevehiclehadbeenrunningwhenparked,butpartswereremovedthroughtheyearsandthishadbeenforgotten.Inothercases,partsmayhavebeenstolenorsimply“borrowed”byotherpeople.

BasicCheckListThereareonlyafewbasicthingsthatneedtobecheckedtodetermineif

there’satleastachancethatabarnfindcanbestartedanddriven.First,itshouldbeobviousthatnovehicleisgoinganywhereunderitsownpowerifitsengineisseized.Ifonehasjumpercables,it’sasimplemattertotrythestarteronvehicleswith6-or12-voltelectricalsystemstoseeiftheengineisfree.Forvehicleswith24-voltsystems,12voltsmaynotbeenoughtoturnanenginethat’sbeensittingforyears.However,onmostvehicles,onecanputthetransmissioninneutral,grabthefan,pushdownonthefan-beltwithonehandtokeepittight,andturntheengineenoughtoseeifit’sfree.Aheftyscrewdriverorsmallprybarontheflywheelteethwillalsoservetoturntheengine.Ifit’sfree,andonetruststheformerowner’swordthatitwasindeedrunningwhenparked,thereisusuallyagoodchanceitcanbestarted.Evenifitseemstobestuck,therearewaystobreakanenginefreeifitspiston

ringsarejustlightlyrustedtothecylinderwalls,asissometimesthecase.Still,I’veonlyhadabouta50/50successrateoffreeingfrozenenginesinthefield,soonemaywanttoconsidertowingoptionsifavehicle’sengineisstuck.Ontheotherhand,ifavehicle’senginecanbeturnedover,thenextstepistomakesure

thatallthemajorandminorcomponentsrequiredforself-propelledmobilityarestillpresentandconnectedtoeachother.Besidesthelargeandobviousparts(transmission,driveshaftandsteering

system),checkthatthesteeringwheelatleasttriestoturnthefrontwheels,evenifthetiresareflatorsunkintheground.Thevehicle’sservicebrakesprobablywon’twork,buthopefullythat’sonlyduetolossofbrakefluid.Forthemoment,makesurethatthebrakeandclutchpedalsareoperationalandstillequippedwithreturnsprings.Smallpartssuchasreturnspringsaresomeofthecommonitemsoftenmissingfromabarnfind.Alsocheckforanacceleratorlinkagereturnspring,alongwithaspringorspringsfortheparkingbrakesystemifspringsareused.Ifanyofthesearemissingorbadlyrustedsotheymaybreak,buynewonesbeforeyoureturn.

Ifthesparkplugsarelocatedinwells,suchasonmostL-headengines,cleanoutallthedirtanddebrissoitdoesn’tfallintothecylindersbeforeremovingthesparkplugs.

Checkthattheparkingbrakeisoperationalandthatitsbandorshoeshaven’trustedinplace.

Eveniftheclutchpedalworks,it’spossiblethattheclutchdiskisrustedtotheflywheeland/orpressureplate.Manypeopledon’tdiscoverthisuntilaftertheygetanenginerunning.Asimplewaytocheckiftheclutchdiskisstuckistoputthetransmissionandtransfercase(ifequipped)ingear,pushtheclutchpedaldown—eitherhavesomeoneholditdownorblockitdownwithastickifworkingalone—thenturnthenengineoverbyhandorwiththestarter.Ifthe

clutchhasreleased,you’llbeabletoturntheengine.Ifnot,eithertheenginewon’tturnoritwilltrytomovethevehiclewhenturnedover.Arustedclutchdiskcansometimesbefreedinthefield,whichIwillexplainlater.

Writedownthedistributornumberortakenoteofitsmakeandmodelandbringbacknewtune-upparts.Evenbetter,removethedistributoraftermarkingitspositionandtakeit

hometocleanandtune-upbeforeyoureturn.Youmayalsowanttobuyanewcoil,sparkplugsandwires.

ReadyToRoll?Nowyouhaveascertainedthattheenginewillatleastturnover,theclutchis

free,thebrakesfunctionandthevehiclehasallitsmobilitycomponents.Butdon’tdustoffyourhandsandwalkawayyet,planningtoreturnanddriveyourbarnfindhomenextSaturdayafterafewhoursoftinkering.Itwouldbewiseatthistimetofillthevehicle’sradiatorwithwater.Aleaky

ordamagedradiator,orrottenormissingradiatorhoses,shouldbeinstantlyapparent.Afterfillingthecoolingsystem,youshouldalsobeabletospotleakingsoftplugsorexternalcracksintheengineblock.Freezecracksinanengineblockarealmostalwayslocatedatthebottomofthewaterjacketandrunhorizontally.Ifcracksarediscovered,theyarenotnecessarilyareasontoabandonyourfieldresurrection.Variousproducts,suchasK.W.BlockSealer,cantemporarilysealengineblockcracks,evenmajorones,andyoumaystillbeabletodrivethevehiclehome,althoughyouwillprobablyhavetogetanotherengine,oratleastablock,later.Internalcracksinanengineblockorcylinderheadarehardertofindbecause

theyleakintothecylindersoroilpan.Unlessyouexpectfreezingtemperatures,leavethecoolingsystemfullofwaterandchecktheoillevelonthedipstick.If,afteryoureturnthenextdayorthenextweek,theradiatorislowandthere’sbeenariseintheoillevel,thereisprobablyeitheraleakingheadgasketorinternalcracksintheengineblockand/orcylinderhead.Ablocksealerproductmaystillenableyoutodrivethevehiclehome,althoughyoumaywanttoputmoreconsiderationintotowingoptions.Theconditionofavehicle’stiresisofobviousimportanceifonehopesto

driveitforanydistance.Inmanycases,whenavehiclehasbeensittingforyears,oneormoreofitstireswillbeflatandthereisseldomaspare.Evenifthe

tiresstillholdair,checkthemcarefullyfordeepcuts,seriousweatheringandagecracks.Onemayoftenbefooledwhendealingwithancienttires;tiresthatarecompletelyflatand/orlookasiftheycouldn’troll10feetwithoutfallingtopiecesshouldnotbeusedtodriveavehicleonroadways.Ontheotherhand,tiresthatlookverygoodwillsometimesdisintegrateinless

thanamile.It’ssmarttohaveatleastonegoodspare.I’vefoundthatevenrottenoldtireswithnyloncordtendtoholdtogether,atleastatlowspeedsovershortdistances,whilegood-lookingtireswithrayoncordmayquicklyfallapart.Largevehicleswithdualrearwheelsgiveamarginofsafety,becauseyoucan

dismountoneofthedualsifitfailsoruseitasaspareforafrontwheel.Inthecaseoffour-wheeledvehicles,buyorborrowatleastonesparewheelandtire.Ifoneormoretiresarecompletelyflat,checkformissingvalvecores,anotheritemoftenmissingonbarnfinds.Thereareinexpensiveelectrictirepumpsavailableatmostautopartsstores,whichmaysavethetroubleofdismountingwheelsandhaulingthemintotownforair.Apumpmayalsocomeinhandyifatiregoesflatwhiledrivingthevehiclehome.

LookOverTheEngineAftercheckingtheconditionofthetiresandmakingappropriateplansinthat

department,examinetheengineagaintomakesurethateverythingitneedstostartupandrunispresentandaccountedfor.Doesithaveallitssparkplugsandaretheyintactwithnobreaks?Whataboutthesparkplugwires,distributorcap,rotorandignitioncoil?Hasthatpre-mid-1950svehiclebeenconvertedfrom6to12volts?Writedownthedistributornumberortakenoteofitsmakeandmodelandbringbacknewtune-upparts.Evenbetter,removethedistributoraftermarkingitspositionandtakeithometocleanandtune-upbeforeyoureturn.Youmayalsowanttobuyanewcoil,sparkplugsandwires.Checkthatthevehiclehasbatterycables.Alsochecktheradiatorhosesandfanbelts.Evenifthehosesdidn’tleakwhen

youfilledthecoolingsystem,youmaywanttoreplacethembeforetakingtothe

road.Oldhosesarelikeoldtires;thereisnoreliablewaytojudgehowlongtheymightholdtogether.Thesameappliestoagedfanandaccessorybelts.Justlikesparkplugsandignitioncomponents,you’llhavetoreplacethemanyway,sowhynotdoitnow?

Itshouldbeobviousthatnovehicleisgoinganywhereunderitsownpowerifitsengineisseized.However,onmostvehicles,onecanputthetransmissioninneutral,grabthefan,pushdownonthefanbeltwithonehandtokeepittight,andturntheengineinordertofix

this.

Forvehicleswithairbrakes,onewouldnaturallycheckthecompressor,airtanksandtheentiresystemforleakylinesorfittings.Vintageairbrakesystemsoftenhaveaseparateunloadervalve(or“governor”)whichmayhavetobeunstuckforthesystemtobuildup

pressure.

AFewOtherAreasToExamineOtherthingstocheckareflexiblebrakelines,fuelsystemhosesandlinesto

theoilfilterandoilpressuregauge.Alsolookattheairorvacuumhoses.Checkthechokecabletoseeifit’srustedsolid.Youwillprobablyneedaworkingchoketostartthevehicle.Ifyoudon’tthinkthecablecanbefreed,takemeasurementsforareplacement.Likewise,checkthethrottlecable,ifthevehiclehasahandthrottle.Handthrottlesarehandy,nopunintended.

Checkthatthevehiclestillhasanexhaustsystem,includingamuffler.Checkthatthefueltankhasn’trustedout.Ifit’sstillpartlyfullofancientfuel,youmayhavetobringbacksuitablecontainersinwhichtodisposeofit.Thesameappliestotheengineoil,whichyouwillwanttochangebeforetryingtodrivethevehiclehome.Youmayalsowanttoremoveandcleantheoilpan,andwillprobablyneedanewgasket.Alsomakenoteoftheoilfiltertype.Youcanusuallyperformalltheseinspectionsinanhourortwo,andyoumaybeverygladyoudid.

Ifavehicle’senginecanbeturnedover,thenextstepistomakesurethatallthemajorandminorcomponentsrequiredforself-propelledmobilityarestillpresentandconnectedtoeachother.ThisJeepchassisillustrationwillhelpidentifythosepartsonapassengercar

ortruck.

WhatWillYouNeedToStartIt?Besidesagoodtoolsetandanypartsyou’vedecidedyouneed,youshould

haveagoodbatteryofthepropersizeandvoltage.Youshouldhaveasuitabletowingchainorrope,andhopefullyachasevehiclethat’slargeandpowerfulenoughtotowyournewtreasureifitbreaksdown.Youshouldhavejumper

cables,extraprimarywire,electricaltapeandcontainersoffuelandwater.Bringatleastaquartofbrakefluidifthevehiclehashydraulicbrakes.Herearesomeotherthingstoconsider:itisn’twisetoattempttodrivea

vehiclethat’sbeensittingforyearswiththeoilthatisnowinitscrankcase.Atbest,theoilislikelycontaminatedwithwaterfromcondensation.Fortheenginesofmostvintagevehicles,buythecheapest30-weightyoucanfind,aswellasseveralquartsmorethanthatparticularenginetakes.Thereasonforusingcheapoilisyoudon’tyetknowiftheenginewillstartorwhatconditionitmightbein,sothere’snopointinbuyingtop-qualityoil.Thereasonforbringingextraoilisbecauseyoumaybreakanoillinealongtheway.Youshouldalsohaveanewoilfilterelement.Bringatleast10feetofeither5/16-or3/8-inchfuelhosewithappropriate

clamps,plusoneortwoin-linefuelfilters.It’sprobableyoumayhavetobypasspartsofthefuelsystembetweenthetankandthefuelpumpand/orthefuelpumpandcarburetor.It’salsopossiblethatthefuelpumpwon’tworkormayfailontheroadandyoumayhavetorigupagravityfeedwithajerrycan.Orthevehicle’sfueltankmayleakandyou’llhavetousethejerrycanconnectedtothefuelpump.Evenifthefuelsystemisoperational,itwouldbewisetoinstallanin-linefilterandpackasparefuelpump.Alsobringrollsofbailingwireandducttape.Gasketpapermightalsocomeinhandyalongwithgasketsealer,althoughyoucanusejustaboutanykindofthickpapertomakeagasket.Besuretobringanoilsquirtcanforlinkages,chokecables,etc.Bringagreasegun,severaltubesofgreaseandenoughgearoilforacompletechangeinthevehicle’stransmission,transfercaseanddifferentials.Asuitablegearoilis90weight.Dependinguponthetypeofvehicle,itscondition,locationandthedistance

andterrainithastotravel,otheritemsshouldcometoyourmind.Asfaraslegality,somestatesissueorsellpermitstodriveanunlicensedvehiclefromoneplaceofstoragetoanother.Expecttomeetthelaw,sobesmartaboutlicensingavehicle.

Whataboutinsurance?Somepoliciescovertheacquisitionofanewvehicleforalimitedtime.Checkwithyouragentorcompany.Buyingliabilitycoveragecouldbewellworththeexpenseifyourbarnfind’sbrakesfailandyourear-endabrand-newFerrari.Ifpossible,makeyourjourneybydaylight.

TimeToMoveYou’vearrivedinthemorningwithallthestuffyouthinkyou’llneed,

includingahelpfulandenthusiasticcompanion,someoneI’veseldomhadsincemysonsgrewup.Theresitsyourbarnfind,althoughmaybenotactuallyinabarn,lookingtwiceasbatteredandrustyasyouremember.Youmightaswellgetdownwiththefactthat,nomatterwhatitsformerownersaid,therewasprobablyareasonwhyitwasparkedandyou’lleitherdiscoveritnoworwhenyoutrytodriveit.Nodoubtyournewtreasurewouldlookmoreimpressivewithairinallofitstiresandtheweedsorcactusclearedaway,butthefirstthingyoushouldgettoistheheartofthematter:willtheenginerun?Ifitwasfreetobeginwithandhasn’tacquiredanothergallonof“oil”since

youfilledtheradiator,youcanskipthenextparagraph.However,iftheenginewasstuck,here’smy50/50successmethodofgettingitlooseinthefield.Removeallthesparkplugsandfilleachcylinderwithbrakefluid.Ofallthe

preparationseveradvisedtofreeupfrozenengines,Ihavefoundthatordinarybrakefluidworksbest.Ifthesparkplusarelocatedinwells,suchasonmostL-headengines,cleanoutallthedirtanddebrissoitdoesn’tfallintothecylindersbeforeremovingthesparkplugs.Astoutscrewdriverorprybarappliedtotheflywheelteethhasmoreturningforcethanmoststarters,andtryingtoturnastuckenginewiththestartermaydamagethestarter.

Ifthetransmissionjustgrindswhenyoutrytoshiftintogear,theclutchdiskisprobablyrustedtotheflywheeland/orpressureplate.Sometimesitcanbebrokenloosebyshuttingofftheengine,shiftingintohighgearandholdingtheclutchpedaldownwhiletryingtorestarttheengine.Ifthatdoesn’twork,tryhavingyourcompanionholdtheclutchpedaldown(orblockitdownwithastick)thengetunderthevehicletoseeifyoucanloosenthediskwithabroad-bladedscrewdriverorlargeknife.Trynottodamagetheclutch–facing

material.

Withthecylindersfullofbrakefluid,putthetransmissioninneutral,getunderneaththevehicleandtrytoturntheengine.Ifitmovesevenalittle,keeprockingitfromonedirectiontotheotherwithyourscrewdriverorbar.Chances

aregoodthatitwillgraduallyturnalittlefartherineachdirectionuntilfinallyyougetacompleterevolution.Turnitoverafewmoretimes,thenhookupthebatteryandturnitoveradozentimeswiththestartertoblowthebrakefluidoutofthecylindersandloosenthingsup.Bewarethatthebrakefluidwillspoutorsprayfromthesparkplugholes;don’tletitgetinyoureyesandbesuretowarnyourcompanion.Cleanandreplacethesparkplugsorinstallnewonesaftercheckingforthe

correctgap.Obviously,wedon’thavethespaceinthisarticletogointodetailaboutcheckingoutthefuelandignitionsystemsstepbystep.AboutallIcanaddinregardtoyourpresentsituationistocheckthe

carburetortomakesureitisn’theavilyvarnishedorbadlycorrodedinside,andthefloatandneedlevalvearefreeandoperational.Useyouroilsquirtcantolubricateallthecarburetor,accelerator,chokeandthrottlelinkagesandmakesurethereturnspringclosesthecarburetorbutterfly,becauseyoudon’twanttheenginetorevoutofcontrol.Iftheengineisadiesel,besureyoucanshutitoffbeforeyoutrytostartit.Whenyouhaveasparkatthesparkplugsandclean,freshfuelbeingdelivered

tothecarburetor,you’rejustaboutreadytoattemptastartup.Butfirst,draintheoldoilandputinthenew.Somepeopleprefertoremoveandcleantheoilpanatthispoint.However,thismaybemoreworkthanyou’rewillingtoperforminthefield.Also,servicetheoilfilterifyoucamepreparedtodothat.Makesurethecoolingsystemisfullofwater.Ifthestarter,generatorordistributorhasoilcups,fillthem.Ifthewaterpumphasalubefitting,greaseit.Makesurethefanandaccessorybeltsaretight.Next,examinetheexhaustsystem.Thatoldengineisgoingtoblowalotof

red-hotrustflakesoutofthepipe.Ifthevehicleissittinginafieldofdrygrass,itwouldbewisetoascertainwheretheexhaustisgoingtocomeoutandcleartheareaofflammables.Theremayalsobearat’snestofdryleavesuptheexhaustpipeorinsidethemuffler.Ofcourse,youhaveafireextinguisherandextrawater,right?Ioncehada

WorldWarII-erahalf-tonDodgepickupsetwhatwasleftofitsbed-boardsonfirebecauseofhotrustflakesblownouttheexhaustpipe.Itmakesanamusingstorynow,butatthetime,itwasn’tfunnytobedrivingavehiclewithabonfireinback.Finally,cleantheengineexhaustmanifoldofanyleavesorflammabledebris.Justpriortostartup,pourathimblefulofgasdownthecarburetor.Bewarethat

iftheenginebackfires,itmayblowflamefromthecarburetorthroat.Keepyourfaceawayandyourfireextinguisherhandy.Likewise,warnyourcompanion.Whentheenginestarts,donotrevitanyhigherthanisnecessarytokeepitrunning.Theoilhaslongsincedrainedoutofallthebearingsandinternalpartsandyouwanttogivetheengineplentyofgentletimetopickupandcirculatethenewoil.Ifthereasonthevehiclewasparkedwasalooseconnectingrodorabroken

piston,you’llfindthatoutsoonenoughwithoutblowingitoutthroughtheblockanddestroyingyourchanceofrebuildingtheenginebyover-revving.Assoonastheenginecanbeidledwithoutyourattentionatthecarburetor,hopintothecabandmakesurethereisoilpressureindicatedbythegauge.Ifyouhaveacompanion,heorsheshouldhavealreadybeeninstructedtowatchthegauge.Ifthegaugedoesn’tregister,shutofftheengineandfindoutwhy.Alinecouldbebrokentothegaugeoroilfilter,oranoilgalleryfittingorplugmaybemissingandoilisspurtingoutsomewhere.Ifyoususpectthegaugeitselfisbad,loosenafittingsomewhereonitssupplyline(orthesenderunitifthegaugeiselectric)andrestarttheengine.Ifoilsquirtsout,thenyouknowthereispressureintheengineandthegaugejustdoesn’twork.Ifyoudohaveoilpressure,checkthewaterlevelintheradiatorandtopitoff

ifnecessary.Somevehiclecoolingsystemscan’tbefilledallthewayiftheengineisn’trunningorthethermostatisn’topen.Alsolookforbubblesintheradiatorwhichcouldindicatealeakingheadgasket.Ifeverythingseemsokay,lettheenginewarmup.Ifthegeneratorischarging,asindicatedbytheammeterorvoltmeter,that’saplus.Ifnot,sometimesafewlighttapswithascrewdriver

onthevoltageregulatorwillmakeitstartcharging.Checkthatthetemperaturegaugeisworking.Ifso,itshouldstartrising.However,ifitkeepsonrisingandtheradiatorbeginstoboil,thethermostatisprobablystuckandyouwillhavetoremoveorreplaceittodrivethevehiclehome.Iftheenginetemperaturestabilizesinanormalrange(usuallysomewhere

between160and190degrees,ormidwayupthegaugedial)trytoshiftintogear.Iftheclutchdiskisfree,youwillknowitnowforsure.Shiftintofirstorreverseand,evenifthetiresareflatorsunkinthedirt,checkifthevehicletriestomove.Alsobesurethatthetransfercaseisingear.Ifthetransmissionjustgrindswhenyoutrytoshiftintogear,theclutchdiskisprobablyrustedtotheflywheeland/orpressureplate.Sometimesitcanbebrokenloosebyshuttingofftheengine,shiftingintohighgearandholdingtheclutchpedaldownwhiletryingtorestarttheengine.Ifthatdoesn’twork,tryhavingyourcompanionholdtheclutchpedaldown(orblockitdownwithastick)thengetunderthevehicletoseeifyoucanloosenthediskwithabroad-bladedscrewdriverorlargeknife.Trynottodamagetheclutch-facingmaterial.Ifthatproceduredoesn’tworkorcan’tbeattemptedbecauseyoucan’treachtheclutchdisk,abouttheonlyotherthingthatcanbedoneinthefieldistotowthevehicleafewhundredfeetwiththetransmissioninhighgearandtheclutchpedalhelddown.

Theconditionofavehicle’stiresisofobviousimportanceifonehopestodriveitforanydistance.Evenifthetiresstillholdair,checkthemcarefullyfordeepcuts,serious

weatheringandagecracks.Onemayoftenbefooledwhendealingwithancienttires;tiresthatarecompletelyflatand/orlookasiftheycouldn’troll10feetwithoutfallingtopieces

willsometimesholdupjustfine.Ontheotherhand,tiresthatlookverygoodwillsometimesdisintegrateinlessthanamile.

Iftheclutchdoesworkandthevehicleseemstowanttomove,orifyou’regoingtotrytotowthevehicletofreetheclutch,thennowisthetimetoattendtothetires.Youhaven’twastedtimeonthem,becauseyou’vedonethingsinalogicalorderbyfirstgettingtheenginestartedandthenfindingoutifthevehiclewillmove.Nowairuporchangethetires,whateverittakestogetthevehiclerolling.Ifyou’reworkinginaflatarea,youprobablywon’tneedtheservicebrakes

yet.However,ifyou’reonahillside,you’llwanttogetthebrakesworkingassoonasthetiresarefittoroll.It’spossiblethattheparkingbrakeisrustedintheonposition.Ifso,dealwiththatnow.Ihavedrivenmanyoldvehicleshomewithonlytheparkingbraketostopthem,butthatwasbackinmycarelessdaysandIdon’trecommendyoudothesame.Hopefully,youcangetthevehicle’sservice

brakesworkingbysimplyaddingnewfluidandbleedingthem.(Thereisanarticleaboutbleedinghydraulicbrakesystemsonpage28.)

DriveItOutOfTheBushYoushouldnowbeabletodrivethevehicleclearofthepoisonivyorjumping

cactus.Checkthelevelsinthetransmissionanddifferentialandaddnewoilifnecessary,orchangeitifyoucamepreparedtodoso.Useyourgreaseguntolubealldrivetrain,steeringsystem,chassisandsuspensionfittings.Youmaywanttoremoveandcleantheoilpannow,butyoushouldn’thavetochangetheoilagain.Checkthebrakelampsandturnsignalstodetermineiftheywork.Ifthevehicle’sheadlampsandbrakelampswork,somuchthebetter,butIdon’tsuggesttravelingafterdark.Ifsunsetisnear,itmightbesmarttocomebackanotherday,ratherthanriskajourneyatnight.Onceontheroad,takeitslowandeasy.Geardownonupgradesanddon’tlug

orhigh-revtheengine.Stoptocheckthetiresandwheelbearingsfrequently(putyourhandonthewheelhubstoseeifthey’regettinghot).Keepaclosewatchontheenginetemperatureandoilpressuregaugesand,ofcourse,listenforknocks,rattlesoranyotherominoussoundscomingfromtheengineordrivetrain.Evenifyougethomewithoutproblems,you’llstillhaveaninterestingtaletotell,whichwillprobablyhelpotherenthusiastsiftheystumbleacrossabarnfind.

BLASTOFF!Cabinetblastingishandy,butinvolvesalearningcurve

ByJohnGunnellWerecentlypurchaseda60-inch-wideEastwooddual-side-openingabrasiveblastingcabinetwithalampandadustcollectingsystem.“Ohboy,”wethought,“nowwecanpopmostofourpartsinthebigcabinetandblastthemcleaninafewminutes.”Afterseverallengthysessionsoftryingtogetsomedirtypartscompletelyclean,werealizedthattherewasmoretocabinetblastingthanmeetstheeye.

Cabinetscomeinvariousmodelsfrombenchtypestolargeunitslikethis60-inchEastwoodmodel.Thesizeofyourworkspace,thejobsyouplantodoandthesizeofyour

compressorallfactorintopickingtherightcabinet.

Thereisactuallyalotinvolvedincabinetblasting,andittakesalotofplanningandmaintenancetoblastproperly.Inaddition,therearewaystoimproveasystemtomakeitworkbetter.Sandblastingisdesignedtouseanabrasivemediasuchaslightsand,glass

beadsorwashingsodatotakedirtandfinishesoffofobjects.Abrasiveblasting

canalsosmoothroughsurfaces.Abrasiveblastingcabinetsallowtheusertoblastwithinanenclosedspacewithoutgettingsandeverywhere.Asiphonsystemisusedtopullthesandfromthebottomofthecabinetand

directitthroughhosestoanozzleorgunthatdirectsitontotheobjectbeingblasted.Becauseit’sretainedinthecabinet,theblastingmediacanbesuckedbackintothesystemandreused.

Blastedpartswillusuallybeleftwithagraycolorandmayberoughifyouusedaroughabrasivesuchassand.Don’tletthemsittoolong,likethispartdid,ortheywillstart

rusting.

TheuserlooksthroughaPlexiglaswindowandcontrolstheprocessbyputtinghisarmsintoprotectiveglovesthatextendintothecabinet.Thefingersoftheglovesallowtheusertomovethehosesanddirecttheflowoftheblastmediacomingoutofthenozzleorgun.Thiscabinetrequiresaminimumairvolumeof20cfm@99-100psi,soaC-

Aire7.5-hpthree-cylinder230-voltcompressorwithan80-gallontankanda34-cfmdisplacementwithflowof27.6cfmwasadequate.However,ourblasterkepttrippingashopfuse,soanelectricianhadtobecalled.Westartedoffusingglassbeadinthecabinet.Whenthatdidn’tstripoldpaint

asfastaswehoped,weswitchedtosand.Sandisaveryaggressivemedia,butitcloggedmore.Ittendedtogetwet,anditalsobecamedirtierfasterthanglassbeads.Silicainthesandmaycausemedicalissuesforsomeusers,sowewentbacktoglassbeads.Whenthemediagetssiphonedupproperlyandflowswellthroughthehoses

andnozzle,abrasiveblastingisfun.Themediacanbefelthittingthegloveswithalightsting,andasthepressureisadjustedwiththefootpedal,themediacanbeseensprayingoutofthenozzle.Ifyoudon’tfeelthemediaandseeitdribblingoutofthenozzle,thereareeithersiphoningproblemsorcloggingproblems(orboth).Whenthereareproblemswiththemediaflowingorifthemediaissprayingin

lowvolume,theremaybeamoistureissue.Moistairdoesnotagreewithsandblasting,sokeepthecabinetinadry,indoorenvironment.Anothercommoncauseoftoolittleornomediaisleakyvalves.Iftheblasterdoesnotseemtobefunctioningproperly,unplugitandcheckallthevalvesonthecompressorandthecabinet,makingsuretheyareallproperlyhookedup.Replaceanyleakyvalveswithhigh-qualitysubstitutes.Moistureordirtcanclogablastnozzle.Ifyoususpectaclog,immediately

stopblastingandclearthenozzle.Useapickordrilltocleanthenozzletip.Sprayasmallamountofairthroughthetubetoblowoutclogs.Abrasivemediacanetchcabinetwindows,makingitimpossibletoseeinside

thecabinet.Mostnewercabinetshaveareplaceableplasticprotectivesheetovertheinsideofthewindow.Replacetheprotectiveplasticifvisionintothecabinetisobscured.Blastingcabinetsneedairtoflowthroughusingtheairinletandoutlet.Some

blastingdustwillescapethroughtheoutletvent,sowearprotectivegear,suchaseyeprotectionandbreathingaids.Runhosesfromtheoutletventoutdoorssothecabinetisalwayspullinginfreshoutsideairandventingtheexhaustoutside.Sincecabinetsandblastersreusesand,keepaneyeontherecycledabrasive

materialandreplaceitonceitgetstoodirtyortoolow.Ifdebriscanbeseenorifthemediaisgettingroundedorpowdery,thenreplaceit.Themediumshouldstreamoutofthenozzleinsteadofcreatingadustcloud.Thesiphoningsystemusesapipeattheendthatyouslipintothemedia

throughaholeinthegrate.Thepipehasasmallventholenearthetopthatmustbeopentotheair.Acarclubwebelongtohasablastcabinetthatwasmodifiedbyamemberwhowasanengineer.Hedeterminedthatthesiphonpipewouldpickupmediabetterifitwasverticallymounted.Aholewascutinthecenterofthefrontedgeofthegrating(midwaybetween

thegloves)andaplatewasattachedtoholdthesiphonpipeataverticalangle.Asecondpipewasthenattachedtothefirstandventedtoit(liketwostrawswithholesintheirsidesmatedtogether),withthesecondpipeinthemedia.Thiscreatedsortofa“carburetorventuri”effectthatdidabettersiphoningjob.Sofar,abrasiveblastinghasn’tbeenthesmooth,easyclean-upsystemthatwe

imagineditwouldbe.Wehavealsofoundthattheinstructionsthatcomewithcabinetsarenotveryinformative.Ontheplusside,thereisnothingtomatchthecleanlinessofablastedcarpart.Themoreyoulearnandthemorerefinementsyoumaketoyourblastingsystem,themoreyouwilllikeit.

Ifyouneedabigcabinet,you’llneedabigcompressor.However,ifyouareblastinginyourhomegarage,itssizeandtheproximityofneighborsarefactorsyou’llwanttothink

about.

GASOLINEANDOCTANENUMBERS:101

Don’tknocktheimportanceoffueloctaneinyourengine

Thefirstethylgasolinetobesoldcommerciallywaspumpedin1923fromthisservicestationinDayton,Ohio.Thedevelopmentofethylantiknockadditivewasspurredby

CharlesF.Kettering,headofGeneralMotors’research,andcarriedoutunderthedirectionofThomasMidgleyJr.

ByWilliamC.“Bill”Anderson,P.E.

Sincetheapplicationofcomputersforenginecontrol,thefearofknockinginengineshasbecomearelicofthepast.Yet,formostcollectorcarowners,knockingremainsaconcern.Thisisparticularlytrueforhigh-compressionenginesofthe1960s.It’snoteworthythatmodernenginemanagementsystemscontrolknockingthewayitwasdonebydriversinthe1920s—retardingtheignitiontiming.Manycarsofthe’20sandbeforehadaleveronthesteeringwheelordashthatenabledthedrivertoadjustthetimingwhiledriving.Knockinghasseveralcauses,butfuelqualityisthemostsignificant.

GasolinebasicsGasolineisacomplexmixture.Themostimportantpropertyofgasolineisits

volatility.Highvolatility,i.e.,easetovaporize,isimportantforeasystarting,quickenginewarm-up,smoothacceleration,andfreedomfromcrankcasedilution.Ontheotherhand,lowervolatilityisneededtopreventvaporlockandtoenablegoodfueleconomy.Toachievetheseconflictinggoalsrequiresablendofdifferenthydrocarbons.Anassociatedconcernisthespeedatwhichgasolineburnsduringcombustion.Ideally,theflameassociatedwithcombustionwillspreadoutwardfromthe

sparkplugsparkinalldirectionsatauniformratetermedtherateofflamepropagation.Thisprocessshouldstartbeforetopdeadcenterandbecompletedshortlyafterprovidingmaximumthrusttothepiston’sdownwardmovement.However,ifthefuelchargeburnstoofast,pressureinthecombustionchamberwillriseexcessivelyleadingtoexcessivelyhighheatofcombustioncausingtheunburnedgasolinetoexplodebeforeit’sreachedbythenormalflameofcombustion.Recallfromphysicsthatasanygasiscompressed,itstemperaturerises,thisistermedtheheatofcompression.Theaudibleexplosionistermedknockingorpingingandproducesashockloadonpistonsandbearings.Ittypicallyoccursatfullthrottlewhenintakemanifoldpressuresarehighest(lowvacuum)leadingtomaximumcylinderpressure.Ifsevere,itcanbreakengineparts;attheleast,itincreaseswear.

Thepressureincreaseduetocombustionaddstothecylindercompressionarisingfromenginegeometry.Anengine’scompressionratioisthevolumeofthecylinderatBDC(bottomdeadcenter)dividedbythevolumeatTDC(topdeadcenter).Thehigherthecompressionratio,themorepoweragivenenginewillproduce,allotherfactorsheldconstant.Althoughengineersknewthiswastruefromtheautomobile’searliestdays,availablefuelsintheearlypartofthe20thcenturylimitedthemaximumcompressionratiotoabout4:1.Abovethatratio,knockingregularlyoccurred.Knockingcanalsobecreatedbypre-ignition,whichisdifferentfromdetonationaftersparkignition.Pre-ignitionoccurswhenthegasmixtureignitesbyanymeansotherthanthesparkplug.Typically,itiscausedbyhotspotsinthecombustionchamber,theresultofcarbondeposits.

ControllingknockThesolutiontotheknockingproblemwasdiscoveredbyThomasMidgleyJr.,

whileworkingasanassistanttoCharlesF.KetteringinGeneralMotors’ResearchCorp.in1922.Hissolutionwastheadditivetetraethyllead.ThisdiscoveryledGMtocombinewithStandardOilofNewJerseyinanequalpartnershipin1924toformtheEthylGasolineCorp.forthepurposeofproducingandsellingtetraethylleadasagasolineadditive.Theuseoftetraethylleadwasusedfromitsinventionuntil1986.Itenabledenginedesignerstosteadilyincreasecompressionratios—1932–5.5:1;’41–6.7:1;’55–7.6:1;’60–8.9:1;’70–10.5:1—tosatisfyanincreasinghungerforpower.Theadoptionofthecatalyticconvertertocontrolpollutioninthe1970sforcedpetroleumcompaniestofindsubstitutesforlead.

OctaneratingsGMandEthylbuiltonthisinitialdiscoverywithcontinuedresearchonthe

antiknockpropertiesoffuels.Dr.GrahamEdgarofEthylconceivedoftheoctanescaleandKetteringdevelopedasingle-cylinder,variable-compressiontestenginetomeasurefuelqualityinoctanenumbersgivingrisetoastandard

acceptedbybothautomotiveandpetroleumindustries.Thisfoundation,coupledwithcontinuedresearch,ledtotheoctanenumberswefindonallgasolinepumpstoday.ThemostcommontypeofoctaneratingworldwideistheResearchOctane

Number(RON).RONisdeterminedbyrunningthefuelinthevariablecompressiontestengineat600rpm,andcomparingtheresultswiththoseformixturesofiso-octaneandn-heptane.Thereisanothertypeofoctanerating,calledMotorOctaneNumber(MON),

whichisabettermeasureofhowthefuelbehaveswhenunderload,asitisdeterminedat900rpmenginespeed,insteadofthe600rpmforRON.MONtestingusesasimilartestenginetothatusedinRONtesting,butwithapreheatedfuelmixture,higherenginespeedandvariableignitiontimingtofurtherstressthefuel’sknockresistance.Dependingonthecompositionofthefuel,theMONofamoderngasolinewillbeabout8to10pointslowerthantheRON,howeverthereisnodirectlink.Normally,fuelspecificationsrequirebothaminimumRONandaminimumMON.TheoctanenumberpostedongasolinepumpsintheUnitedStatesisthe

averageoftheRONandtheMON,(R+M)/2.ThisaverageiscalledtheAntiKnockIndexorAKI.SometimesitmaybecalledthePumpOctaneNumber(PON).Therefore,the(R+M)/2octanewillbefourtofivepointslowerthantheRONnumberthatwasusedaloneinthe1950sand’60swhenpetroleumcompaniesregularlytoutedtheiroctaneratingsformarketingpurposes.

Althoughtheforegoingstandardsapplytoall,agasolinefromonebrandcanbedifferentfromthatofanother.Forexample,consideronecompanythatblendsaRONof91withaMONof83andanothercompanythatblendsaRONof90withaMONof84;bothfuelsproducea(R+M)/2of87.ThefuelwiththehigherRONwillhaveslightlybetterresistancetoknock.Refiningisahighvolumebusinessandprecisecontrolisnotalwayspossible,leadingtovariationswherethe(R+M)/2isslightlymorethantheminimumof87.Finally,eachcompanyhasdifferentadditivepackagesthatcouldslightlyaffecthowthefuelreactsinagivenengine.

ThebottomlineUseofpremiumfuel(higheroctane)inanenginethat’sdesignedforalower

gradewillnotproducemorepoweroreconomybecauseoctanehasnothingto

dowiththefuel’senergycontent.And,it’sheatcontentofthefuel(energy/unitvolume)thatdeterminesitseconomyormilespergallon.Conversely,usingalowergradefuelinahigh-compressionenginedesigned

forpremiumfuelwillproducelesspowerandeconomybecausethecomputerwillautomaticallyretardthetimingtopreventknocking.Thesameresultscanbeobtainedinnon-computercontrolledenginesbymanuallyretardingtheenginetiming.

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