Full Custom Ian Roussel Rebuilds The Rear Window And Top Section Of A 1940-41 Chevy Chop Top 🤓

[Music] boo welcome back doesn't look anything like a Volkswagen or a Jeep does it nope picking up with Dave and red and myself left off getting to this side of the action it's starting to come together all the same details that we went through on the other door are now being attended to so I'm just kind of working this out I got this stretched into position but now that this is all secure I want to address the rear of the window and the roof how it flows uh Dave and I and red had screwed that panel in place just to look at it and it's really important the placement of the window uh we're using the original the older back window glass and Surround so we got 41 or whatever here we're using the early window to splice into the later model body so it's a bit of a challenge uh we three thought that it looked better a little bit of a different shape I wish I had the early frame here still but I do not so I just took it out taped it up and we're going to sit it back in there and discuss I cleaned up the back and the top and the in and the out and before we put this on there was six hands in the room only two see how this go us hopefully it doesn't just fall right through that's about what we had right there cool yeah that's where the screw Hol is lined it up just like that I standing back and looking at it and that's what's really important in a chop you want it to you want the windows to look like they're on the same plane around the belt line and then the flow you know some cars you'll want to just kind of go right down like a fast back and others you'll get the little double bubble that's what this is doing it just looks like this window's too high I'm looking at this Dimension here it's hard to see with the pole in the way can you push the car back at all yeah little Readjustment on the angle of things now you can the whole idea is you got your belt line then you got your window line and looking at it as this Belt Line wraps around you got this much space right here when you come here it's kind of works there I see what you're saying it looks like the window's just up and that's really where it could go wrong so basically you have your windshields your side windows and then why does the back window look like it's way up on the roof I've seen that before four and uh the back of this window and Dave and red and I talked about this also you see how flat this is this really worked with the uh earlier car so we thought well shoot you know the bottom of this window or the top of the window is curved what if that was the bottom we looked at it like this you know and then it's really out of whack so that's kind of what we're working with just that's the window I don't have another one the curvature of the glass actually works perfectly so I think thing to do is just drop this as low as we [Music] can cuz uh see this is fairly straight across from the deck lid so as they come together I don't think it's going to bug me that much that you have this kind of roundish Belt Line and a very flat back window or straight through on the bottom Edge but I think we're going to have to drop this a bit I'm going to get out that measuring thing and just check a couple pieces just to say from the Belt Line we're working at like two roughly yeah we're going to call that 2 in right to the roll on the window and from here two and a half here okay two and a half so we're even on that so I think I'm going to come down at least a half inch probably 5/8 just because I do I don't want to look too high I'd rather look a little bit low so yeah I'm going to measure up two and a half and then give or take a little bit yeah we're at two and a half for sure this one just seems to be a little bit taller just a smidge so just come in at five why did I grab a silver marker all right back to work five these now I don't know I don't know who is cutting this but look at that not not naming any names but that's it's definitely some work we're going to have to mediate so now I can just kind of eyeball it because we're getting a pretty good line yeah something in that area cool set that back down give it a [Applause] [Music] [Applause] cut [Music] [Applause] what's going on at the house today we're getting our flood mediated we got a service that came in no thanks to the insurance company but we got a crew we might have to break off back and forth uh some guys that came in the van a bunch of dehumidified and our house leaked like crazy I don't know I can't wait to see what develop I wasn't looking for a major construction job but it flooded in there so pretty bad that's what's up man what a mess what a mess shock it so when we put this together there's just weld in here so I'm going to clearance around that that much see I just make that little Notch I drop it in what am I hitting on the inside now hit Jack standand uh the rear window frame is hitting something the inside sheet metal is coming into play We're have to cut that that be cleared up a little bit of action that direction yeah all right let's step back and take a [Applause] [Music] look fortunately we're able to weld that structure right back into place which is cool like everything else the more times you fit it up easier it gets still hitting something measure that see where we're at same thing we're at two right here we're at two right at the corner yeah so yeah we're going to have to put a little bit of a sheet under there because that don't look so hot I can get a clamp believe right there it is perfect cool all right so I'm just looking at this by our uh screw holes and it looks like this has got to come this way just a bit that window has got to be centered we already set that up right there we agreed okay cool all right so I'm just going to spot this in and then talk about these roof caps the saell panels this area is really critical and we didn't really come up with a plan for that I'm hoping to use pieces of the other roofs but this is like where the whole thing really matters you could see I'll put a little wire on this this is where it really starts to count right through here so right when you're looking at that wrap around that's pretty close then we're have to see that that's where it all changes right through there so this is going to come up just a hair which will help that transition see somewhere in there but I think we're have to cut through here and do something in that general area but I'm going tack the bottom together first looks like that come down even lower huh I'm looking at this I mean I guess no that works that's what we're going to have to pay attention to that curve right there CU this matches that and that cool get a couple clamps for for all right just doing these two sides because as I lift this it's going to change this area and you can see how flexes a little bit I don't want to pull that down I don't want to sink this panel through here so set the roof skin on there see what we're dealing with what see this is even the earlier car it's got a reasonably good flow but but it's too narrow which is what happens all the time with shop tops but all in all I'm not opposed to that it's low there of course I hate welding across the center of stuff but that's where we're at with this project we're going to have to do it why do you hate welding across the center of stuff because when you weld we know that things shrink so that's perfect that's that's a shrink right nice sh it's not you your ch's just thinking about what's to come over there oh so you're gonna have to cut this down the middle so that it'll fit on both sides uh I'm definitely not going to do that it's this seam here look at that monster look at that see look how out of shaped that is right oh that's where you're going to have to go down the center oh boy no way around that one that'll be another video for another day you have stress dreams about it having stress dreams about the other night that was weird so I think yeah the way that that flows in is good yeah and I think as we were describing we're going to have to come in with two kind of panels they'll just be like so yeah the way that look at that that's just about perfect having me one clamp in there and we're there so just wish this was a little bit wider look at that like it would be perfect if it was two inches wider this now we got a right and a left look at that like little there I don't know maybe I'm G to cut it down ring just thinking about it I mean I'm a competent welder so to hear a guy like me go you know that's a tough will oh there's a big screw through this thing look at this like why isn't the panel lining up someone took the liberty of putting a large screw right through the roof skin oops Yeah so there's that let me cut that screw off and see if we can't get this to line up that's where we're at that's our angle I mean you can't go wrong there I mean you can go wrong I mean you can't argue it that over here look at that I guess what we're going to do we're going to widen this on the table put this cap back on I'm widen this I guess three inches we want that to come out widen it two inches going to square this up on the table had this a seam in the center of the table that I use all the time I'm just going to Center this on the seam and kind of gauge if this thing is pretty symmetrical here to there we got 26 here to there we got 29 inch half 27 and a half close enough for me we're just going to check this here we're running from 16 and a quarter 13 and a quarter 16 and a quarter so here 16 and A4 13 and a half yeah so man for a freehand cut that's pretty close so the line of the table gives us that reference see so now we have a estimate of the center same thing here look down and we're going to cut straight through here you see how much I enjoy that let's cut [Applause] [Music] [Applause] [Music] [Music] [Applause] it going to clean these up a [Applause] bit this is a cool thing I've talked about before but for interior stuff like this whether it be undercoating or this type of stuff I use a sawall a lot of times watch how it works it's such an effective scraper so because this is turfed you can see it's going to need a little shimming it's going to raise this up these little shims and I'm kind of looking at this right here got a cool little thing it's just like a base plate right and you're looking at that and you're even we want to stretch it two inches actually just pull this that way that's symmetrical I'm to pay attention more to the center line I think there yeah there cool we want to stretch it too with that Mark two two do the same shim it take some of that stress out there look at that okay you can see these are reasonably close there's one thing I like to do with stuff like this uh a lot of people will just take a 2-in band and set it in here sure that's cool but when I'm doing something like this I double the material up on a seam like this so I'm going to put a wider strap on the inside I'm going to tack that in place then from the outside I'm going to put that band in that way it's double thick metal it's not going to distort but first i'm going to clean that up with the wire wheel there is a bit of debate there's a bit of debate on people uh how they prepare their joins like this but any day I'm going to choose stronger than weaker so sure if you do TIG weld it you set it up perfectly all the way through Hammer weld Etc I'll see you in a week I'm going to get this done in about an [Music] hour [Music] need a piece about three foot long see what we got all right cool so what you have here is a definite flat surface and that's where the join across that roof comes into trouble because you got nothing to really gauge it on uh I have a flat bar I'm going to create for that but you see how the setup makes all the difference where I can push down on a table right here and then kind of build that with a clamp so I'm going to make I guess a 3 inch piece yeah I'll do two and a half keep it on the uh no I'll do three we'll keep it way 3x 36 coming up I have a question yes why did you just do that hit it with the hammer see how it's not perfectly straight uhhuh when you cutting with the shear it creates stress so a lot like the shrinker uh it will shrink or stretch the metal in places so each time I pull down on it there's that little tick tick tick so it caused it to twist so I was just hammering out those spots of imperfection it also looks professional busy it up a bit you look very busy cool so I'm G to clamp this bring over the welder attack it Are We R ready doctor name of the game here don't overheat [Applause] anything and as it shrinks you want to control it as we know control is everything you ever torque down a cylinder head I have no idea what that even means well the first time you do you're going to remember this this is the part where you ask what's the comparison doctor what is the comparison here with what I don't even know that's you told me to ask you that torquing down a cylinder head yes I don't even know what that even means well well okay so torqueing down means like torquing down someone offered us a torque wrench so you're tightening something mhm and cylinder head a cylinder head is on the [Music] engine it's alive yes pretty much when you have a large flat area like a cylinder head you'll have lots of bolts in it and you don't just like you don't just put one right down you go around and around and around so everything settles right in did I not go around and around and make it settle right in you did all going to say I'm doing it halfway but what's not to like about that so I don't understand what do you mean doing it halfway well so many people uh you see like the strict Pros they have all these Cleo Fasteners and all this setup and they're doing this and that and the other thing and hammering and I just did that in five minutes yeah the second strip goes in and that thing ain't going nowhere that's going to be Mega strong with the emphasis on Mega keep it a little bit small so it fits right [Applause] here why see that's what we're going to be dealing with on the roof of that car right make a one and 3/4 inch so this is what I was describing so each time I stop there's like a little bit of a different stress on the level so that's what I was flattening out with the hammer they have these things it's a Shear but it's just one drop it just bang it just chops and it's a perfect stress free Cut so it's a little give and take in everything see how it's kind of curved that's I was doing I was taking that stress out kind of feel it's very very curved that's the stress I was taking up and also if I run the sander on the edge of this I'll take that little sharpness off and that will take some stress out too yeah all right so take a little bit more of that now actually put it on a brake and just flatten it where I can't Reach Clamps let's put these screws in you see where I'm going with this is uh you know the double layer that is super strong so now you have a really good foundation because it's going to have filler up there and you know you're leaning on it sing Etc this is just going to be a really strong brace hit this real quick and with this Gap here you see how you can see the metal underneath mhm so that's what I'm welding I'm welding these three pieces together that's really strong because it's uh so thick now I don't have to be as cautious with the welding because it's a much uh Stronger pound less likely to work with just a tack now I'm going to slide this over and come up under here with some clamps going to put on my ear protection and do a little hammering on this yeah so what I was doing was keeping the crown on that the crown [Music] hey throw it on that roof see what we got wow it fits I like that I think you can see where we're heading yeah I like that right there yeah it looks good cool so I'm going to trace where that window is so we can get this out of the way of the glass you'll be able to pull that right in her glass is about that far up going to guess on this cut it and then reassess I'm trying to keep it a little bit low trim to fit make a couple marks there so we know where it [Music] sits whenever I'm working with a dome like this this I always try to float it in the center cuz every time you hit it or do whatever you can uh potentially flatten it or distort it so give a little support in the center cuz we want to retain that Crown want to retain the crown [Music] no [Music] weird little ding right through there yeah pretty close I'd say yeah I have to take that a little bit but for now I'm going to work with that cuz I'm going to start to screw this together yeah it's going to want to be up there me get a stick in there see what we're measuring raise up the roof I'm going to raise the roof all right so I'm just trying to get a rough estimate on the height yeah so again looking at side profiles making measurements calibrating gauging the phase of the moon all the things get into the ballpark I'm going to put two screws right in the center of that just to check so here's the thing the window see I want to push it up just a little bit like that going put another stick in there try to push it then maybe tack it let's see that oh yeah there it is right there times just look out yeah so I see they see me slicing right here and here because it's going to be three layers thick of metal right here I'm going to slice slice push and then weld I'm going to take that little Edge out right there too and it is overlapped pretty big on the inside but I'm going to leave it like that and then come back from the inside and cut out all that extra metal this pad cut out from inside ATT this instead it's getting way just going to put a tack on on here cuz it's starting to get away from me it's such a close lap the clamp can't really handle the [Music] truth it's too bad look at this side this one's going to work out there's a little mismatch in the uh cutting on that so we're going to have to patch in that corner little forethought goes a long way but this is going to work just nice so I'm going to just address this right here cuz this whole cross is going to be a setup the cross weld I'm going to I got this situated back here but I'm going have to lift this up clean both sides of this and do some prep just going to trim right through here to kind of get a line representing what I need just leave it loose but with one screw you'll get the look of the side profile of the car are you satisfied with how this turn out oh yeah yeah looks really good [Applause] [Music] all right so one step closer this is again what I was addressing uh the sale panel is really what's going to sell the whole thing by having this window looking like it's in alignment with the others uh you don't get that weird humpback effect you'll see some sometimes if you just kind of put the roof cap in place with the window and everything so yeah a lot of times it's a three-piece sometimes you can make a full one piece came up short on that side but easy fix going to clean all this up next time we're going to get into the over the top weld that's why I just left it screwed got to get in there and clean it up side profile is looking good e love [Music]

Channel: Full Custom Ian

Views: 145,848

Keywords: Ian Roussel, full custom ian, ian roussel full custom garage, ian roussel custom cars, Ian roussel cars, ian roussel full custom garage youtube, YouTube Ian roussel, Ian roussel youtube, custom car builders, hot rods, custom fabrication, full custom garage, Ian roussel full custom, Ian roussel custom cars, volkswagen, vw, bug, type1, volkswagen bug, beetle, fusca, cox, ianrussel, bajabug, ratrods, carrestoration, hotrodbuild, vwbeetle, customcars, genewinfield, eonrussel, ionrussel, chop top

Id: msIxbUNsrxQ

Length: 43min 38sec (2618 seconds)

Published: Fri Dec 29 2023