To see the full feature of this Model A sedan, make sure to check the Nov. ’23 issue.
Part 1: Custom Chassis & Flooring For The Model A Sedan
By Ron Covell – Photography By Chris Gray – Illustration By Eric Black/eBDCo
Gerry Kerna is an avid gearhead with an eclectic collection of outstanding cars. She, yes, Ms. Kerna wanted to build a state-of-the-art Model A sedan in the mildly channeled style and when she found a suitable 1930 Ford sedan body, the project commenced.
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Eric Black did the artwork that helped get this project off to a great start.
Cornfield Customs chopped the body 4-1/4 inches and then sent it to Roadster Shop to have the chassis built, along with an extensive list of body modifications. This car has so much special work that it will take a several-part series to cover the project in sufficient depth. Mark Giambalvo of Creative Rod and Kustom was charged with the final build and assembly.
Roadster Shop did a full CAD design of the chassis, using styling cues from a ’32 Ford, keeping it low to the ground and carefully matching the contours of the Model A body.
Roadster Shop is well attuned to cars of this period, and they went to great lengths to give it a traditional look while incorporating the latest technology and build techniques. The frame is completely custom designed. It looks similar to a 1932 Ford frame but there were many modifications needed to work with the Model A body and have the aggressive, low stance Kerna wanted. The profile of the frame was made to follow the contours of the A-body, and the ’rails were pinched to match the width of the 1932 Ford grille shell. A special, super-low front crossmember was designed to allow the frame to flow forward from the firewall without a kick-up, which is an awkward-looking modification often to get cars this low.
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The front crossmember uses a unique underslung design, cradling the POSIES Super Slide Spring from the bottom.
The rear of the frame was kicked up 8 inches to clear the rear axle. This was done as a gracefully sweeping curve rather than using an angular Z-shape. A beefy X-member was added to the frame, substantially increasing the stiffness.
The motor mounts are completely unique, and on the driver side the steering box mount is integrated with the design.
The iconic reveal embossed on the side of a 1932 frame was repositioned, starting precisely at the firewall and ending in line with the rear wheel well bead. The wheelbase was stretched to 107-1/2 inches, 4-1/2 inches longer than a Model A. The body was slightly channeled over the frame in the manner of a 1932 Ford.
Because the frame rails are so low to the ground, the steering tie rod runs above the frame. Special steering arms were machined from billet chromoly to position the tie rod at the correct height.
The engine is a 1956 Cadillac V8 engine, which is perfect for the vintage style of the sedan. Watch for more articles detailing the exceptional work done on this car. (The Model A sedan appeared on the cover of the Nov. ’23 issue of Modern Rodding, and inside is the full feature.) MR
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With the front suspension assembled, you can see how the steering linkage works. The drag link runs below the tie rod to its own steering arm, and the frame is notched on the passenger side for clearance.A clever mount attaches to the front of the frame, providing a platform to support the radiator. The tubular extensions on each side are the headlight mounts.With the radiator mounted, you can see how efficiently the components fit together.The chassis was built with a beefy X-member, providing torsional stiffness. A platform perfectly matches the contours of the frame, which will become a structural part of the body.The Strange 9-inch rearend has a four-bar system and a sturdy Panhard bar. The one-piece, laser-cut 10-gauge inner body structure is clearly visible here.A special sheet metal cover was fabricated to cover the arched rear crossmember, which provides clearance for the third member. Airbags will suspend the rear of the car.A snugly fitted sheet metal cover was made to cover the five-speed TKO TREMEC transmission.A one-piece cover was made to hug the driveshaft. Everything was sized to give adequate clearance but maximize space inside the body.A transition piece was made to connect the transmission cover to the driveshaft cover. All the seams will be TIG welded and metal finished.Here, you can see how the driveshaft and transmission cover mate to the body substructure.Elaborate, laser-cut metal guides were made for the intricate embossing applied to the floor and firewall panels.Here, a Pullmax machine is used with the custom guides to form the detailing on one of the floor panels.This is the rear body floor panel. You can see how superbly the guides work to make the stepped and embossed designs.One of the larger floor panels is fitted into place here. Note how the graceful three-element design theme is repeated on these panels.Here is an overview showing how the floor panels fit inside the body. This kind of detailing takes time, but it helps to eliminate drumming and vibration inside the car.A new metal firewall is being flanged by working over a hammerform. A mechanical shrinker was used on the tightly radiused corners.The firewall is shown a little farther along, featuring the embossed designs and the recess for the distributor.The cowl top was removed and smoothed and is being carefully fitted before welding it back in place. Next time, we’ll look at more extensive body modifications.
