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Project Aero.

Part 3.

The Havas Conversion Continues.

January 2010.

The Right side outer fender was welded back on and the seam filled. I made some good progress today.

My new tunnel support finally arrived from the metal shop on New Years Eve day.

Tunnel Support welded down and fit like a glove. I've also cut out the hole for the handbrake.

Finished up the last of the floor/chair supports and cut the little bulge out so the last two rear support beams will lay flat.

On the last stages of all the re-enforcing pieces. This 2 part V bar will tie the tunnel and rear together.

V bars and tunnel section welded together. It's all done, this was the last piece of extra steel.

The nice part is that I can still have access to the Variomatic since the lid slides under the rear bar.

I test fitted the rear bench. I'll need to modify the bottom frame so it sits lower over the new framework.

The fender is mounted, but still needs a lot of work.

New sheet metal going in under headlight.

Last piece of the engine compartment surround welded in.

There is a small deck piece missing here that needs to be there.

New piece in place.

Finished some small welding in the engine compartment, mounted the Rack and Pinion steering and painted the lower frames.

It looks much better.

Still need a small piece welded in near the bottom but it's almost done.

The Daffodil sure looks good...considering what I started with. This is now 5 months into the project.

Passenger side really looks good but the trunk and rear areas still need help.

Last piece of damaged meteal on the right front fender.

After forming and welding in a new piece of steel this problem has been solved.

Work has begun on the left "Havas" door.

Outside skin cut out.

Everything cut out and trimmed.

The internal braces (holding the inner & outer skins together) all welded.

The welding has just started on the opening.

A lot of work goes into a HAVAS door conversion.

Adding the top plates is time consuming and very labor intensive.

Inside corner is shaping up as well.

Started to install the full length sill plate.

Sill plate done, First coat of filler and another step plate welded in. It's coming along nicely.

The inside sheetmetal all completed...all that is left is to add the filler.

All the step plate pieces are in and the door chains installed.

The modified Jeep Wrangler door hinges bolted on.

Passenger side door hinges also finally got mounted.

Aero showing off it's new nose. Next to tackle that rotted hood.

The Daffodil hood is in bad shape. The nose is rotted and so is the back where the hinges mount.

My solution: Take two hoods to make one good one. The back of the old 750 hood is good so both were cut.

All new steel pieces are being applied to the nose section.

Both halves are now welded together.

Five new pieces welded into the nose section and a first layer of filler in place.

The hood is now back in one piece with a few coats of filler.

100% better than what I started with. The hood is now solid inside & out.

Instead of using the single prop rod to hold up the hood I'm using gas pistons...they work really good and the hood won't warp now.

This is the inside of the windshield surround (inner and outer skin).
It will need to be sealed in order to support a convertible top.

Detail view of how the upper door pillar was enclosed with new metal.

Started to seal up the inner window frame.

Windshield frame enclosing is all done so it's ready to mount a new convertible top.

Based on the DAF/Volvo 66 Fender Badges...I'm designing a set of Fender Badges for Aero.

Here is the finished custom Fender Badge.

Fender Badge mounted (temporarily) in it's proper place.

Dressed up the front end a little to see how it would look.

The edge of the trunk lid has been eaten away.
It seems I will never be able to put the Electric Shears and Welder away...more stuff keeps appearing.

A few new pieces of metal welded in.

Also a few on the left side.

A lot of straightening on the top of the trunk lid along with the new sheetmetal it is starting to look good again.

Added some gas struts to the trunk lid today.

What a mess! I have to rebuilt the entire rear valance...inside and outside.

Where the spare tire sits. This has to be the worst area of rot I have to fix yet.

This is what remains of the left rear quater panel & spare tire holder from the inside...nothing except rust.

I have to start re-building the rear quarter from the inside.

A little re-enforcing and re-shaping around the back corner has given enough strength to replace the outside quarter panel.

Decided to start doing some of the major filling on the body to make it look more presentable.
Even though there is lots of metal underneath the body is still wavy.

Time to bring AERO up on the portable lift so work underneath can be done.

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