Car Restoration - The Metal Surgeon,US

1
The Metal Surgeon.
2
I have 21 years experience in shaping aircraft
and automotive materials from the flat to all
desired shapes.  My expertise using the English
Wheel has lead to jobs for many design houses in
England, Europe, and now the USA.  I am now
located in Denver, Colorado as a custom metal
worker with my own  fully equipped work shop. I
served a 4 year engineering  apprenticeship with
Jaguar in Coventry, England.  My first project
involved the XJ220 an all aluminum bodied super
car, which held the crown of Worlds Fastest
Production Car for 3 years, until being taken
over by the stylish Mclaren F1.  The XJ220s
panels were initially all hand formed, until a
low volume run where they were part pressed and
then finished by hand.
3
1959 Porsche 718-006 RSK Spyder Restoration
Part 2
This series of posts will cover the build of this
unique 1959 Porsche 718 RSK Spyder. Out of
thirty-four 718 RSKs made by Porsche, this is
number six, an unknown number survive. Well
continue with the right bodyside rebuild, we
patterned from the left body side. Rolling the
pattern to shape the Porsche 718 RSK body panel
4
1959 Porsche 718-006 RSK Spyder Restoration
Part 1
This series of posts will cover the build of this
unique 1959 Porsche 718 RSK Spyder, the successor
to the legendary 550 Spyder.  The 718 RSK Spyder
contains nothing superfluous it could serve as
a blueprint for all Porsche models for that
reason the quintessence of speed, purity, and
simplicity. The aluminum three-part body shell
covers a tubular space frame made of seamless
steel. The interior is also stripped down to the
essentials two seats, three pedals, a simple
handbrake, and the gearshift. Out of thirty-four
718 RSKs made by Porsche, this is number six, an
unknown number survive. Well start with the
right bodyside rebuild, we patterned from the
left bodyside, that was deemed correct after much
research. Building a Datum box to aid an aluminum
Porsche reconstruction front body half (upside
down)
5
Mercedes Unimog Custom Fabrication Part 5 Final
Results
Delivery of the Unimog is complete! Heres the
final product delivered and after our work was
done, onto paint/graphics and assembly, undertook
by Couch Engineering.  Check out the final car
restoration results displayed at a convention in
the photos below. This post wraps up the build of
this Mercedes UNIMOG, Part One shows photos of
the Unimog at delivery and photos of the first
stages of Module 2 fabrication.   Part Two covers
the Module 2 roof fabrication,  and the Module 1
door inner structure reconfigured to take out the
wheel arch.  Part Three looks at how we bonded
the outer skin to the inner structure of module
number 2 and the floor fabrication.  Part Four
covered fabrication of the tailgate and rear of
the Unimog.
6
Paint and Assembly 1953 Porsche 356 Pre-A
Cabriolet Part Six
This post takes us to the end of the journey for
this project where we are in the final assembly
mode of Porsche restoration to get the 356 Pre-A
Porsche Cabriolet back on rolling wheels, as it
came to us. This is part six of a series of
posts covering the Porsche restoration of
this 1953 Porsche 356 Cabriolet, taking us
through the final paint and mechanical assembly
of the body.  The introduction post on
this Porsche restoration 356 Pre-A shows pictures
of how the Porsche came to us, then after
dismantle was complete, and then after the body
was media blasted.  Post two covered
the beginning of the nose rebuild, leaving the
new section TIG welded into position.  Part three
looked at how the rest of the front end of the
Porsche was repaired. 
7
Custom Interior Fabrication 1938 Chevrolet Pepsi
Truck Custom Build Part 13
This post takes us to inside the cab where we
have completed the classic restoration, i.e
fabricated a few custom pieces for the interior
of the Chevy cab.  This post will cover how we
created the windshield defrost vents, cab vents,
and duct housing, followed by the shifter housing
build. First, we show you how to accomplish
custom metal work with the aid of simple tooling
from the scrap bin.  This kind of tooling is
invaluable when performing automotive classic
restoration, whether going for custom made
creations or original body styling.  Not only is
the tooling going to be simple to make, its
going to be super cheap!  The example job is
making a pair of windshield defroster/heater
vents for our 1938 Chevrolet Pepsi truck
dashboard.
8
The Metal Surgeon for more information 3852 South
Kalamath Street Englewood, Colorado 80110
(email Valerie_at_TheMetalSurgeon.com) or phone us
at 303-761-4884!