Modern Rodding Tech
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Adding unique details to the sedan's interior. A special instrument panel was CAD designed to fit the 1932-style dash
1. It’s time to add unique details to the sedan’s interior. A special instrument panel was CAD designed to fit the 1932-style dash.
Building a 1930 Ford Channeled Sedan
Part 4: More on Details
By Ron Covell Photography by Chris Gray
W

e’ve all heard the old saying, “The devil is in the details.” As we look at some of the last tweaks made by the crew at Creative Rod & Kustom on Gerry Kerna’s Model A sedan, you’ll see how careful attention to small details can make a car stand out.

For the dashboard, rather than use a complement of standard round instruments, a decision was made to design a unique bezel that follows the top and bottom contours of the 1932-style dash with three uniquely shaped openings. After the details were worked out in CAD, the bezel was CNC machined from aluminum. Classic Instruments was called on to build custom instruments to fit this panel, and it is the perfect example of modern technology used with a vintage design element.

A removable hatch was needed behind the seats for easy access to chassis-mounted components, and rather than use a flat plate, a highly detailed panel was designed with a convoluted outer edge, stiffening ribs, and recesses for the mounting screws embossed with dimple dies. Once painted body color, this panel brought one more point of interest to the interior.

The seat backs and lower cushion frames were also covered with sculpted metal panels. Again, adding just a few ribs and steps to these panels gives them a lot of character. They add a nice contrast to the soft leather upholstery when painted body color.

The fuel filler cap was positioned above the left rear wheel and fitted into a neat recess. When you see it, it looks “right,” but if the cap had not been recessed, it would protrude awkwardly.

The Cadillac engine had to be mounted relatively high in the chassis to get proper ground clearance, leaving little room for a traditional air filter. The solution was to design a cantilevered filter with the element on the passenger side of the engine, using three low-profile runners to direct the air into the throttle bodies. Ninja Robot did the machine work on these parts. Not only did this solve the clearance issues, but it also added a unique detail to the underhood area.

The chassis was initially set up with traditional tubular shocks behind the headlights, but a plan was hatched to make this a unique detail. A clever bellcrank arrangement was designed to mount the shocks on the inner side of the framerails, entirely hidden by the hood sides. Taking this concept one step further, the outer portion of the bellcrank was designed to look like a vintage friction shock–something rarely seen these days. Roadster Shop fabricated these components, which were installed by the Creative Rod & Kustom crew.

Kerna wanted a vintage license plate from her home state of Pennsylvania, but these are virtually impossible to find in salvageable condition. The solution was to machine a new plate from aluminum in CNC. As you’ll see, after careful masking and painting, the raised lettering and keystone symbols give this plate an authentic look.

If you missed the article on the finished car, it was featured in the Nov. ’23 Modern Rodding (and on the cover). Now you can look at the car with fresh eyes, understanding the tremendous effort put into getting every detail just right.

The bezel for the instrument cluster was CNC milled from billet aluminum
2. The bezel for the instrument cluster was CNC milled from billet aluminum.
Here’s the bezel after machining and finishing. It’s a unique and stylish design
3. Here’s the bezel after machining and finishing. It’s a unique and stylish design.
Classic Instruments custom made the gauges, a focal point for the interior
4. Classic Instruments custom made the gauges, a focal point for the interior.
A sheetmetal panel was designed for the area behind the seats and the metal was hand shaped to suit
5. Sometimes, a handmade sketch is sufficient to make complicated parts. A sheetmetal panel was designed for the area behind the seats and the metal was hand shaped to suit.
The metal panel captures and improves the drawing's flavor
6. After some careful work with a Pullmax and some dimple dies, the metal panel captures and improves the drawing’s flavor.
The smaller inset panels can be installed to get the full effect
7. The smaller inset panels can be installed to get the full effect. The carefully proportioned ribs add strength and character to these panels.
The seatbacks were carefully fabricated, too, incorporating the ribbed theme used on the previous panel
8. The seatbacks were carefully fabricated, too, incorporating the ribbed theme used on the previous panel.
With the seatback installed on the frame, you can get a good feel for how the finished seats look
9. With the seatback installed on the frame, you can get a good feel for how the finished seats look.
A custom base was made, too, and you can see how beautifully BUX Customs sculpted the foam
10. A custom base was made, too, and you can see how beautifully BUX Customs sculpted the foam to make the seating extremely stylish and comfortable.
With the seat frames painted and the upholstery installed, this car's interior is striking
11. With the seat frames painted and the upholstery installed, this car’s interior is striking.
One minor detail on the exterior was mounting the gas cap in a location that’s easy to access
12. One minor detail on the exterior was mounting the gas cap in a location that’s easy to access. The cap will be slightly recessed to provide a very smooth look.
The cap installed in the recess with the welds finished and smoothed
13. Here’s the cap installed in the recess with the welds finished and smoothed.
A custom design was needed and a quick mockup was made from cardboard, exhaust bends, and tape
14. The Cadillac engine had to be mounted relatively high in the chassis to get proper clearances, which left little room for an air filter. A custom design was needed and a quick mockup was made from cardboard, exhaust bends, and tape.
Ninja Robot made a CAD model so the part could be CNC machined from aluminum billet
15. Once the basic dimensions were worked out with the mockup, Ninja Robot made a CAD model so the part could be CNC machined from aluminum billet.
Here’s how the machined parts came out. This would be challenging to make by hand
16. Here’s how the machined parts came out. This would be challenging to make by hand.
The air filter fits in the tight underhood area, allowing plenty of room for a good-sized filter element
17. In this shot of the finished car you can see how beautifully the air filter fits in the tight underhood area, allowing plenty of room for a good-sized filter element.
The outer portion of the bellcrank is designed to look like a vintage friction shock
18. A late modification was adding unique, bellcrank-operated shocks hidden inside the framerails. The outer portion of the bellcrank is designed to look like a vintage friction shock.
The bellcrank mechanism and linkages were made by Roadster Shop and installed by Creative Rod & Kustom
19. The bellcrank mechanism and linkages were made by Roadster Shop and installed by Creative Rod & Kustom.
These assemblies were laser-cut plates from steel plates along with some CNC-machined aluminum components
20. These assemblies were laser-cut plates from steel plates along with some CNC-machined aluminum components.
The telescoping shock is hidden from view when looking from the inside of the framerails
21. The telescoping shock is hidden from view when looking from the inside of the framerails.
It’s virtually impossible to find a salvageable Pennsylvania license plate from 1930, so a new plate was modeled in CAD
22. It’s virtually impossible to find a salvageable Pennsylvania license plate from 1930, so a new plate was modeled in CAD.
The custom license plate fresh from the machining center
23. Here’s the custom license plate fresh from the machining center.
The plate after being carefully sanded, masked, and painted
24. Here’s the plate after being carefully sanded, masked, and painted. It certainly has the look of an original plate. One more detail that helps make this car unique.
SOURCES
Modern Rodding
VOLUME 5 • ISSUE 49 • 2024