Chop Cut Rebuild 1956 Chevy Convertible Part 1

this is chop cut rebuild real cars real tax real deadlines posted by dem woods jump-cut rebuild when a builder takes on a project there's a number of things they have to consider the car is just the easy part they actually have to think about what resources they have the skills of the build team and the availability of parts well that last problem just got blown off the scale so guys now that you have it here in your own light what do you think what's gonna need a lot of work then yeah I would say so and we have new team members right yep we got a couple of additions we've got Craig Craig great oh great so we had a - but only one name that'll make it easier for me uh all right let's get some glasses and gloves and get at it right hey my name's Edgar solar and I work here for classic you know participating in the build this time around we decided to take on a 1956 convertible Chevy Belair he found this car through a couple of friends and it was up in LA and we want to put a look at it it looked a little rough from from where I was sitting but you know until you get the car part you really can't judge what you got now that we own it we'll have to make it to make it work making this Bel Air work will require more than a little effort well it may not be all together or even close to running it does have lots of parts and trim that aren't easy to pick up pushed it out onto the street push it up onto the trailer lashed it down and let's start at the front we know there's fun involved because we saw a smile on the face of the guy who sold it to us as we drove off that's the most fun he's had in a long time my name is Craig Jaffer's and I'm the lead tech for the chop cut rebuilt before we got involved in trying to park the car it was pretty rough I mean you could already see that the rockers were arrested floors were rusted through quarter panels were caved in so we knew it was gonna be a challenge going in building this car hey pop still works that's a good sign the reason we went with this car is that there aren't a lot of convertibles out there we wanted to showcase the products that classic industries offers for the new tripod there's very few out there and the ones that are in great condition are pretty pricey 35,000 we got a deal you know the guys always ask me to do the tricky work like removing parts that have fluids in them because they know I've got a level of expertise second to none to measure area it's moments like those that really challenge my dry sense of humor basically since this is a new project for us we really wanted to clear everything out and see what we're working with we wanted to check out the canvas to see you know how we're gonna approach the repair and rebuilding of this car I don't know if I'd call this correct canvas there isn't even any of it left on the roof well when we're pulling the parked car we realize there are a lot of things with didn't read fenders are a little on the Impe side we might be able to reuse those not too much rust in them but the floor pans are gone the rear quarter panels are gone to be honest with you I think that this car it was really bad shape I mean most every body panel on it had some type of you know rust or damage from collision say the dash is probably one of the best pieces that I saw that was still intact hope you're gonna reuse this are you well this point we don't know damn we might have to restore it or maybe go a different route oK you've got other manufacturing socials too for these okay yeah okay yeah suppliers are gonna love this project right now I can see is just the parts that came off the car probably the only thing we can reuse there's lots cool probably use in this car not to reuse them we'll probably need them as a reference to know what the new parts should look like kind of like getting a description to a police sketch artist mark reducing the crack here I mean this is not gonna survive and it's cracked on the other side to come on Danis still of weldings you good at welding there is no way this car is going to look like this well I think we can do it maybe sure how Dan can come up with a good alternative to not having to replace every piece of sheet metal on this car I think there's a solution here you find another car well in your own catalog on page 175 real-deal steel thing to help us mmm whole body right and assembled in the USA where these guys located I think you're in Florida I love to travel so is there any of this metal we're gonna reuse you won't be able to use this piece of metal these new guys catch on quick this is chop cut rebuild presented by classic industries America's first choice in restoration and performance parts California builders get a lot of credit for creating and restoring great cars but that skill isn't exclusive to the west coast the East has their fair share of top builders too Joe damn good to see you nice to see you so are you going to be the solution to our problems Dan I think we can help you out with this let's go outside meet my partner Randy great i'm joe whitaker co founding partner of real-deal steel Jan I'd like to introduce you to my partner reindeer Irwin hey Dan nice to meet you nice to meet you Randy Randy Irwin Sanford Florida and I'm one of the owners of real-deal steel the folks asked us to build a 56 Chevy for them they had purchased a car that was in bad enough shape that it needed a new body a replacement body is this gonna be our 56 once this is all put together you'll have your 56 Chevy convertible real deal takes two products from multiple manufacturers and puts them all together they don't make them they just make sure it fits it's just like a giant 56 Chevy convertible jigsaw puzzle there are 52 individual pieces required to put our 56 convertible together the lift and rotisserie system in the fixture system allows us to take those pieces put them all together and build a finished car that fits it looks like a 56 ship so how does all these all these opinions of work actually these pins on the platform K into existing holes in the factory floor braces so once we pull it down it's perfectly square perfectly flat perfectly true this jig or fixture is the key to maintaining a quality product with consistency once the floor is on the rotisserie then the fun begins we install piles and piles of fixtures that are going to line up all the rest of the panels to come then we begin installing the other panels the first panel to go in when the fixtures are in place is the cowl and firewall panel heavy grade steel is used to create each fixture to ensure it won't change or Bend each time it's used once the CalFire wall is in position it is then by script to the forward leading edge of the floor pan and then we get to the good stuff we start to spot weld it in place Pat Dan helping us with the spot welder and that was great the spot welders are huge and in some instances you have to have two people one driving it and one shooting it maybe even a third that knows what he's doing everything went well until we got to the passenger side front corner and these spot welders are water-cooled because we use them so fast that water is circulated through the spot welder dan did not break the thing it's just one of those things that happens we cleared that last comment with our insurance company just to be sure once the cowl was completed and welded we moved on to installing the rear inner corner structure very little of the metal going on at this stage it's a stuff you'll be able to see these are the panels that give the body support and with this being a convertible body there's more than the usual amount of Steel giving support to the exterior panels next piece yes sir the rear inner wheel well portion of the inner quarter structure has to be by script into place with lots of vise grips because you have a lot of metal there that has to move into just the right position our biggest expense opening this place was buying nine hundred ninety dollars worth of vise grips but you've got to have those we've got a vise grip on the when we're putting panels together we've got a vise grip at about every two inches so it squeezes the metal together so that when you spot whether you don't blow holes in it we probably used about 20 vise grips to hold it in place as we spot weld there and spot weld we take them out of the way and just keep going across nine hundred and ninety-nine dollars of pliers sounds like one of those bad road trip songs the fifty-six convertible that we're assembling for classic industries is going to be very similar in appearance and in construction to an original fifty-six convertible that would have been built back in 1956 we've had some people that worked in the assembly plants back then tell us how similar our fixtures are to the fixtures that they used to build real fifty-six Chevy's if beauty is only skin-deep then what real-deal steel has planned for us next there's a lot of beauty it's day two at real-deal steel which means at the end of this we should have a real-deal body when Dan got here this morning first thing we did was start getting everything together for the outer skins to make the skeleton look like a car the first thing we removed were the outriggers in the trunk area that locate the inner quarter panels to the trunk fixture we brought the outer quarter panels over to the inner quarter panel set them up in place held them in place with the tech screws and made sure that we had the proper trunk gap from the inner quarter panels to where the trunk lid is gonna go these are the kind of minut details that make politicians ask the question can you build it in my district once the risk folder panels are in place we then take the trunk fixture out and then the deck lid goes on or in this case a test deck lid that we use to final tune the fit of the quarter panels now is when we get to put Joe in the trunk and close the trunk uh awesome whenever I see stuff like this happen it makes me wonder if these to discuss this step before they went into business together or if they just thought it was fun and they would take turns out bring it on down Dan and it will actually adjust it left to right and front to rear rough it in that looks pretty even right there till we pull the package Tran which will actually pull the quarters in or will scoot the difference and go ahead and bolt it up right about there Joe thank you ready and then the package tray goes on to achieve the proper position on the border palace in addition to that panel the piece behind the deck lid and down low is installed to determine the bottom of the trunk gap you may have noticed that some of this metal has different coatings well that's because it doesn't all come from the same manufacturers some of it is even salvaged I don't then we started removing the rest of the fixture the H fixture is very heavy and once the quarters are installed it's a little hard to lean over and pick the whole thing up we don't like to walk through the center of the car put our feet inside the car so we use the forklift to pick up the H carried out of the way so now we take this fixture out right yep the first one in is the last one pushed you can walks out of the way on each side pick it up and out of the floor and all of a sudden this beautiful shiny body is free of blue fixture it's a it's a far body on its own now we then move to installing dashboard a fix - is a feature which disappeared on later cars but in the 1950s it was a key part of the support structure that is spot-welded all across the Finch wall plans just behind and then it's welded down underneath and all the sudden it goes from DNA kind of an empty loose looking cow assembly to a car up front the hinges go on next they go on the calendar the doors go on to the hinges getting it the hinges up in there to tell dawn with four bolts and getting your fingers up in there and behind there it's a bit of a trick to get the hinges bolted to the Cal these guys know every trick there is to assembling these cars including how to make other people carry over the heavy parts the doors bolt on to the hinges with three bolts we only used two we're just aligning the door for now making sure the door fits the opening properly and make sure the rocker is set with the door the door is set with the quarter panel when the passenger door was initially installed and tightened up we shut it and get fit pretty well classic industries new 56 convertible is born here in Florida and the new baby will be shipped from Florida all the way across the country to Southern California to its new home where it will ultimately be turned into a running driving car this car is the epitome of what we try and do on top can rebuild real cars real techs real shops and now a real-deal steel 56 Bel Air body this is chop cut rebuild presented by classic industries America's first choice in restoration and performance parts your car is meant to get you on the road turns out you can also be on the road to get your car this is Seattle Washington and the bel-air isn't going anywhere if we don't come here first everybody's got their dream classic car but before you think about this style to make the model year the color the horsepower you better think about what you're going to put it on at Art Morrison they always think about that first hey Craig dance how you doing good you ready to show me the shop yes I am let's go my name is Craig Morrison with Art Morrison enterprises I took Dan on a tour of the facility so you can see what we do and how we do is what is all this stuff all this material here is basically the raw material for doing our chassis we have a mill whole file that would run 48,000 pounds of Steel for us at a time that comes out on a flatbed semi truck and we warehouse it you're the shop and you've got scratching ground - yeah it all depends on what the particular project is whether it's ground cube or rectangular tube and it gets cut and bent up where does that happen it's right over here so the next station I took Dan to was the processing of the tube itself the first machine that all the tubing goes through is just a bandsaw to cut it into length and then from there it will get measured out for the bends that they will receive so what happens now okay so what Matt is gonna do is now that the tubes all marked up he's gonna take it over here to the fender and we're gonna go ahead and Bend some tubing yes I did offer my expertise with benders but it turns out you need to be clear-headed for this job I took Dan over to the jig table and we got to watch the frame get loaded into position and tack welded into place so how many jassi's have been in this fixture well but Seema time this year we'll have hopefully I sold the thousands chassis out of this table thousand chassis za oh that's a lot of tripods it's a lot of trifle the name is not Smith and I I build a tri-five chassis our Morrison under prices when Craig brought Dan over I was busy putting in the rear end on the tri-five and he helped me uh tack and weld up a couple of uh brackets and whatever customer gets chassis number 993 I apologize now so after the tri-five chassis gets pulled out of the jig table it then goes to the rotisserie and we were able to take Dan over and show them one of our other chassis as that one was being flipped over and some of the final welds being put into place so over here again this is where we do all the assembly of our chances before they they go ahead and ship out the next stage that I took Dan to is in the chassis assembly where we got to see the actual chassis the classic Industries is using go ahead and put the front rear suspension on and crate it up and get it down to classic industries ok you don't know more Dan was nice to meet you Morrison Enterprises do all the quality control and final frame assemblies so what we'll do is we'll start with putting this tube in the back here we'll go with this end of the housing I've got adjustable into the front we'll use a second hole when I gave the bar to Dan I explained out how we go about it we usually start with the rear bolt or swing it up into the the upper hole position but that's the desired location I like that desired location is really a polite way to say Dan do it like this so after the rear suspension was assembled in the chassis we went ahead and moved forward to the front suspension front suspension on this chassis is nothing like it was in 1956 this is comfort and control the final step of the front suspension assembly process was bolting the rack and pinion in place it replicates say 79 to 93 Mustang rack-and-pinion was a sort of the industry standard for steering component aa Craig there's three things you never discuss politics religion and Ford parts being used on a Chevy just kidding you can talk politics if you want and now chassis number 933 is ready for shipping yes it is awesome I don't know if 933 is a good name for a car I'm sure there's a number of options I'm really excited to see this car that classic industries is putting together because it will have the great classic body style of 55 to 57 Chevy with the modern-day handling of a new car in less than a week the guys at classic industries are going to have a new toy to play with and thanks to the people that aren't Morrison in Seattle it's gonna be on four wheels the past few weeks have been stressful for the team at classic waiting will do that to you they've been keeping busy getting organized and finally it's their turn to jump back into action good morning morning so here it is 1964 Impala chassis 64 that's what you wanted right well we can always use a 64 but just 5060 what's first first thing we do is let's get out of the crate okay gloves and glasses right yep okay we started with the armored taxi and blasted it out of the crate it's a little rough to get something out that heavy flat Dan was kind of like a kid at Christmas all we had to do was really give him a crowbar and let him have that it sings beautiful down to the welds to the cutouts for the exhaust I mean this thing's gonna handle really well it's too bad we got to put a body on it but we'll definitely feel the effects of it more driving it the way that the chassis looks coming fresh out of the crate you can slap a coat of paint on it put it under your ride and be ready to roll all right Craig so what all do we have here so we've got a coil overs we've got a curry third member sway bars all the mounting brackets and that front coil overs over there all right so what do you want to do first yeah let's tackle the rear end first we've got the third member in hang the coil overs near the rear sway bar all right work in the back all right good we're installing the rear coil overs strange sent two coil overs with fully adjustable so we can adjust the dampening we can actually adjust the stiffness of the softness in the coil spring so the lower mount had a bushing installed into it we had we just had to press it out once we press it out fit no problem on the lower shock stone so what happens if you don't have one of these Ranger heavy duty shot presses with a 20 ton capacity in your garage how do you get this out well to do that it's not not as difficult if you have a vise it opens up wide enough I could almost put this in a vise you know and press it out into your oh gosh Bryce okay yeah because really this is a glorified fight right right okay all right heavy 20 tons Art Morrison Enterprises has been working with strange engineering for years like Morrison strange is a family-owned business that earn their knowledge at racetracks around the country and implemented that knowledge into consumer and performance products from a two-car garage in Illinois they've grown into a one hundred and twenty thousand square foot facility that was top you want to hold that for him siddhart Morrison chassis came to us with a rear housing there wasn't a third member so we got the third member there were axles on curry we did have to press in the studs to hold the rear end to the hold the third member to the rear in and then once we got that then went ahead and dropped the third member in we didn't really have to put ceiling or gasket in it right now cuz we're just walking it up yes everything we're doing will be undone later on you got to be sure everything fits while it's still okay to scratch stuff so which way is this gonna go this is gonna go underneath the rear end and then these will hit the for the heim joints of the front of the frame Bart Marcin provided for us a full-time joint sway bar unit that mounts cleanly into their frame hidden by some aluminum plates if you weren't looking for a chances are you wouldn't even know it was there okay so this is gonna be a little more complicated because we go for the axle end right we got the curia actually at the wheel would brake drum Wretch's emergency brake right the rear brakes same size rotor which is a 13 inch rotor well we went with a four piston caliper in the back setting the axle into the axle tube with the parking brake shoe bracket takes a little patience practice and caffeine-free effort the wheels that we got there they're a 13 inch rotor so they'll work with anything bigger than a 17 the 17s in the front was only 18 from the back these brakes will fit perfect and things stop really nice you're putting that big of a wheel you need that big of a brake you get these guys in put 24-inch rims on their car but neglect the brake system they're the guys that are at autos on or a parts store changing their brakes every two weeks you know diffs and discs can be difficult but I think we caught a few breaks today this is chop cut rebuild presented by classic industries America's first choice in restoration and performance parts wow the deliveries keep getting bigger and bigger don't they yeah we got that one big real deal steel one nice what are you doing well we got to pull the calipers off because we're gonna make this a roller and the roller tires that we have clear the couch okay so Dan alright we had to our Morrison chassis on the lift we have the real-deal steel body so we need to kind of swap positions with those so we went ahead and put some spacesaver spare tires on that chassis so we can roll it out of the way and put the body on the lift she was down on the ground and ready to roll we moved her out of the way and let then have his fun with the forklift after a little bit of instruction to make sure he didn't run through anything valuable he actually did pretty good if he ever wanted to quit his day job he could be a forklift driver I'm not sure why but I often hear the phrase if Dan ever quits his day job and I don't know if that's a suggestion or a referral we went ahead unbolted it from the pallet and we were able to lift the body up in the air and drag the old pallet out we're able to roll the chassis underneath the body and then start to bring it down slowly aligned everything up it's not like you can just drop the body on your chassis and run from there you're definitely gonna have to expect to even do some modifying adjusting we're lucky we can get these bodies at this point we have to take what we can get you know you just can't assume that it's gonna be all ready to roll kind of thing you have to be prepared put a little working once again it comes down to body work versus body fun and a little work is good for the souls it can certainly keep you on your feet this little note for my friends at real-deal steel right right it says please test fit all front sheet metal to check correct fit offenders and foot this car has never had any doghouse Madeline doghouse what's what's doghouse metal they're referring to the whole front clip really fenders grill everything like that okay so should we put some doghouse in my Helana yeah we got the full rolling body and chassis down on the floor and got it over to our fab area okay so we put the sheet metal on right right we have sheet metal yeah we've got the original hood which was one thing we can save okay we've got the fenders off another car that we can use and we also have a special core support that we need a special one special one be cool sent us a core support radiator setup it's the whole thing okay great all right now let's get it and start slapping it off alright get our doghouse in shape okay you want this here yeah you can put that there okay this is a much different look than this right this is the original one the original core support and be cool has a complete set up this has got the core support it's got the radiator I mean even look at the back here I mean it's even got the fans local fans built-in I mean this just thing's ready to go we chose to be cool because we've got this LS engine we've got some horsepower and they built this radiator to what we wanted you know as far as Inlet and outlet for the radiator hoses with the fans the cooling the fan switches everything that we need for our engine to cool better they provide it for us how many caps do you need on this thing when you got the overflow for the radiator yeah radiator cap and power so the power-steering is coming into here right right okay so they think of everything be smart be smart all right what's next well let's grab the fenders and hang goes okay although you would never use fenders as your point of reference for panel alignment it's good to have some original pieces available to see if things are at least in the right zone Eddie motorsports sent us some really nice trick put hinges with gas shocks and roller bearings and a really nice stuff so we bolted those to the firewall we put the hood on now the hood is one of the only thing we were to say from the old car so everything's bolted up we still have a little bit of alignment and adjustments to do on it but we made some good progress today even before we got this radiator we knew this ride was going to be cool the classic team had waited weeks to marry the Bel Air's body and chassis after they arrived it made sense to send them on a honeymoon more Craig Morgan how are you good how you doing I'm doing great so it's all one color now all one color that's great how did this go well you know we had Ares do the soda blasting on it because now it's all one

Channel: realdealsteel567

Views: 126,459

Keywords: Classic Industries, Real Deal Steel, Chevrolet (Business Operation), Dan Woods, CCR, Chop Cut Rebuild (Award-Winning Work), Speed (TV Network)

Id: pNd1r1WRss4

Length: 26min 57sec (1617 seconds)

Published: Mon Mar 02 2015