Car Restoration - The Metal Surgeon,US

1. The Metal Surgeon.

2. ABOUT 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 XJ220’s 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 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. We’ll 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 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. We’ll 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 Mercedes Unimog Custom Fabrication: Part 5 Final Results Delivery of the Unimog is complete! Here’s 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. Mercedes Unimog Custom Fabrication: Part 5 Final Results 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 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, it’s 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. Contact Us The Metal Surgeon for more information 3852 South Kalamath Street Englewood, Colorado 80110 (email: Valerie@TheMetalSurgeon.com) or phone us at 303-761-4884!