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Project Aero.

Part 2.

Finally Coming Together, 2009.

November 2009.

This the motor side of the strut support. I have already removed the top plate so that a full length plate can be welded in place.

Strut support all finished with new full length plate.

Not much left of the engine mount rails...this is the left side and would not hold up anything.

After a 1/2 day of welding new plates in, it looks almost as good as new and will now support the motor again.

Driver‘s side fender done now with most of the major work. All that is left is some last minute details.

The upper firewall will need a new strip welded on.

New full length section welded in place at the top of the firewall where the hood rests.

Cowl edge and Fender edge has new metal strips and are as good as new.

This is some of the web of support bracing needed to make the cabriolet project safe for the road. There are a few more pieces at the door sills and front.

Today I started to weld in some of the new braces. This piece is one of the new main braces.

Top cross brace and angled braces welded in.

This brace crosses over the tunnel for front support.
I ended up changing it a little from the plans by notching in for the gas and brake pedals (I didn‘t think there was enough room for full movement).

Starting to add the upright supports to tie the door sill together. I‘ve decided to add another brace which was not in the blueprints either.
This one will go across under the dash and tie the uprights together.

Upright and cross braces in place. Notice the re-enforcing bar under the steering bracket.

The Driver‘s side is pretty much completed after adding the last pieces of bracing and blending it all in with a first coat of filler.
The center upright is another deviation from the original plans.

Nice clean lines at this corner. The final touches will be done later on after the floor is put in again.

Inner door sill brace added. This is one of the required braces which ties the front to the back.

The rest of the rotted floor boards were cut out to make it easier to work on.

The floor support bracket is in place.

Another needed piece was the left rear side panel brace. This is a 3 part brace which had to be welded together first before installing.

Passenger side cross brace now in place too.

Passenger side firewall sil and fender area needs some serious surgery.

Here‘s the mess underneath the Passenger fender.

There is no saving this door/hinge support pillar.

"New" door pillar and upright support all welded together.

I made a slight modification to the original DAF bodywork.
DAF had a brace in the upper corner between the pillar and inner fender...I installed something heavier.

Spent a long time today fabricating a new passenger side door sill frame using pieces from old sills.

Door was hung again to adjust the fit.

Passenger side sill now about 90% completed and the door has been rehung.

Passenger side still needs a lot of work. It was a beautiful late November day (sunny and in the 50‘s) so I cleaned up the workshop and took AERO out.

The Driver‘s side looks a little better. The car looks like it sits high because right now there is no Motor or Variomatic primary and she sits on 14" wheels.

New hinge support plates made from 1/4" Aluminum. Much stronger than originals.

Same as I did on the other side...a full panel was welded onto the door pillar.

Those huge rust holes that were are now filled in with new metal and at least this corner is also sealed up.

Passenger side top sill and inner wheel well almost completed. Lots of new sheetmetal on this top corner.

Now to tackle the bottom half of this inner fender.

Five new panels so far and it‘s just about done. This wheelwell was easy.

Wheelwell completed and almost ready to install the outer fender.

Temporarily the Hood and outer fender were put on to check alignment...Looks good from here.

Right side engine support rail is worse though.

Using some of the old engine support rail to fabricate a new one.

A new plate will have to welded on the strut support since this side is also rotted.

What a job! The right side engine support and strut tower are finally finished.

Passenger compartment is starting to shape up but it‘s still a "Flintsone Mobile".

The first floorboard/seat support welded in place.

Red DAF 31 chair test fitted and 2nd support rail ready to weld.

Completed the seat support frame on the Driver's side today. I‘ll be ready to put a floor in on this side very soon.

Seat anchors found. I'm using 1 1/8" muffler clamps and they work perfect.

Belting Along (the magazine from the DAF owner's Club in England) did a surpise 6 page feature on Project: Aero in their December 2009 issue.

Decided to do something radical to the Cabriolet. I‘ll save the original doors and use my spare set from an old 750 sedan parts car.

After cutting out the desired shape the "HAVAS" panel was test fitted.

Braces were added in between the two panels to form a step.

Front corner re-enforcing plate secured to windshield frame.

After welding the rear seam it was filled in to blend in a nice flat body.

New homemade full length sill in place which overlaps the lower door panel and covers that seam.

Started to form and install the metal cap plates on the "HAVAS" door opening.
These are a lot of work due of the curves so it has to done in sections.

Here is a photo of the door cap from the inside.

Here is how to bend metal. This is the third cover plate on the new door opening before it was shaped into a top plate.

Three plates in place and partially blended in. One more piece to finish up and the "HAVAS" door opening will be done.

The fourth and final top plate is in place along with the eye-bolt for the "HAVAS" door chain.

The "HAVAS" door opening is done, except for some cosmetic work which will come later.

Inside of door opening is also completed now. This was a very long project to complete.
And I still have the other side to do.

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