We previously looked at how the crew at Rad Rides by Troy, under the efforts of Adam Banks, scratch-built a body for Ross Myers’ fenderless 1936 Ford Roadster. While a new (or modified) body is most often fitted to an existing frame, they took a different approach here: waiting to design the frame until the shape of the body and grille shell were finalized. This allowed them to do an exceptional job of integrating the fit and contours of the two components.
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The grille itself was completely scratch-built from steel, and while it retains the “flavor” of a stock 1936 Ford grille, it is sectioned 4-1/2 inches, and a complete shell has been built from 18-gauge steel to surround the grille. As you’ll see in the photos, this was a massive undertaking. The grille of a car really sets the essence of the build, so this was a component they had to get right.
The first step in building the custom grille was making templates for the curvature of the stock grille bars.
Since this will be a fenderless car and much of the frame will be visible, they decided to add a “rib” to the bottom of the frame rails, somewhat like the detail on a 1932 Ford. Special dies were made for a Pullmax machine to shape this unique detail. This will become one of the many striking features of this cutting-edge project.
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Another unusual feature this car has is a removable X-member. This was done to ease the job of painting and detailing every square inch of the chassis to an impeccable level. If you’ve ever tried spraying, blocking, and polishing the paint on an X-member, you can appreciate how beneficial it would be to disassemble these components, allowing much better access to all the nooks and crannies. The X-member was formed as two channels, with a length of ½-inch bar welded to the inner edges. This gives the components additional strength and a more-finished look.
Each grille bar made from 1/8x¾-inch cold-finished steel bar. The curve was made by shrinking the back edge. Heat was required at the bottom of the bar to attain the tighter curvature.
Torq-Set aircraft-grade fasteners are used to hold these components together. Troy has used these on some of the Bonneville cars he has built, and they are made to extremely high standards for both fit and strength.
We think you’ll love seeing all the detailed work being lavished on this car, and you can look forward to many more articles showing the later stages of construction. MR
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Special braces were laser-cut to hold all the bars in registration. The notches were sized to be a snug fit on each bar.The center bar was made from 16-gauge steel sheet, bent into a channel, and curved to the proper contour.Each bar was meticulously fitted, then trimmed for a precise fit.Here’s a side-by-side comparison of the new grille with the original. You can see the new grille has been sectioned considerably.Curved stations have been temporarily attached to the top of the grille, to guide the shaping of the cap for the assembly.New sides were made, too. Note the carefully embossed linework on the panels.New sheetmetal was shaped to make the “chin” portion of the grille shell.The 1/8-inch steel was carefully fitted to the back portion of the grille assembly, giving it plenty of stiffness. You can see how beautifully all the pieces fit together.With the grille held temporarily in place on the chassis table, you can appreciate just how gorgeous it is. With the key body components positioned, the chassis layout can begin.Chipboard is used to mock up the shape and location of the framerails. Great care is taken to make sure that all the shapes blend well together.The bottom edge of the framerails will have a raised rib, reminiscent of a ’32 Ford frame. These are special forming dies made for the Pullmax, which will make this detail.The front portion of the frame has been run through the forming dies.After careful consideration, a decision was made to taper the height of the rib as it progresses toward the front of the framerails.The center portion of the framerail was shaped in a similar manner, and here it’s being test-fitted to the body.The rear kick-up of the frame was formed separately and seamlessly joined to the front portion of the rails.The top and bottom flanges of the frame are shaped and tack-welded into place.The inner boxing plates were given some tasty detailing with the Pullmax, too.This is the boxing plate for the center of the framerail. Note that flat platforms were provided for attaching the removable X-member.With all the components for each framerail tack welded together, the assembly is positioned in a sturdy fixture and carefully TIG welded together.The X-member was formed as two separate channels. Here you can see the intricate bolted endcaps that will allow disassembly.Each portion of the X-member is accurately positioned and tack welded to the framerails.Here’s a close-up of the junction of the X-member and the frame. The quality of fabrication is superb from every angle.With the framerails completed, the attachment of the body and the fitting of the floor panels can begin.Looking toward the front, you can see how beautifully the body, chassis, and drivetrain fit together.
