1939 Ford pickup - Nastruck With Betty Davis, Uh...Mini Cooper Eyes

Only one side of the new surface design was created in clay. The wooden buck was designed to eliminate this procedure on the passenger side.

The lines on the inside of the plaster cast were an important aid in creating the wood buck. Measurements were taken and recorded for the buck ribs.

It appears as though the two centerlines are the new headlight and the original fender center.

A wood buck was created using a tongue-and-groove method of assembly. The beauty of this buck is in its ability to be disassembled and turned 180 degrees to make the perfect duplicate form for the passenger-side fender. As you might imagine, there are many, many hours of fabricating involved.

When it came time to mount the lights in their permanent positions, a great deal of measuring was done. First, the crew leveled the chassis side-to-side. Next, they added a 3-degree rake from front-to-rear. Then, they positioned and aimed the headlights using cross-hair marks based on the Mini Cooper's headlight beam lines. They also created a site gauge to ensure the lights were exactly in the same location side-to-side.

When it came time to mount the lights in their permanent positions, a great deal of measuring was done. First, the crew leveled the chassis side-to-side. Next, they added a 3-degree rake from front-to-rear. Then, they positioned and aimed the headlights using cross-hair marks based on the Mini Cooper's headlight beam lines. They also created a site gauge to ensure the lights were exactly in the same location side-to-side.

One of Just Dream'N's employees, Chase Frueh, begins to hand-form the 18-gauge sheetmetal. He uses a shot bag and mallet to curve the piece to fit the wood buck. Then, the English wheel was employed to smooth the shape perfectly. These pieces were butt-welded together with a TIG welder. After that, much hammer and dolly work smoothed the weld seams until they became invisible.

A variety of shapers and sanders were used to work the various pieces of metal; they were to be temporarily joined together with Cleco clips.

Also, different-size wheels were used in the English wheel to smooth the various curves in the metal. The curved-metal shapes were actually formed by the mallet and shot bag.

To temporarily hold the lamp in place, a 1/8-inch rod was welded from the headlight assembly to the fender. This support will be removed later when the new surface is completed.

Chase begins with smaller pieces that will be welded together. A large piece would be difficult to manage in the English wheel.

Several pieces were joined together to make the new headlight opening for the fender.

As the pieces were created, they were connected to the original fender with a metal clamp called a Cleco clip--a special metal-working clamp.

The lamp appears to be leaned far back, but it's in precisely the same position as on the Mini Cooper.

At this point, the fender seams and surfaces were leaded and primed to prevent any further surface rust. The temporary support structure was removed from behind the new fender surface.

Notice that the large fender shape with the new headlight shape creates a complex surface. Add to this the fact that the hood sides were welded to the fender, and it becomes a very complex piece. The engineering to make the panel seams fit precisely is a long and laborious process.

Here's a detail shot of the headlight. Notice that the front air dam has been created under the fenders and grille.

Here's a completed front end photo in primer. This truck will be quite unique in design; some will think it's an improvement, others may prefer the original. To each their own!

Here's what critters on the highway will see bearing down on them. The front of the '39 Ford has a pleasant face and somewhat cartoon-like appearance with big oval eyes. However, this fast lil' hauler was created to blow the devil himself off the road.