Vintage truck owner Randy Jackson of Brighton, Colorado, is a NASCAR fan. He owns this '39 Ford pickup with an oval grille that he regards as one of the less attractive designs from Ford Motor Company's design studios of the '30s. Nevertheless, he wanted something special to attend rod runs and other motor events in, and he selected the Golden, Colorado, shop Just Dream'N (owned by Russ Tilkes) to reconstruct a seriously modified vintage hauler from his homely 1/2-ton. The brief instructions to Russ were, "Make it fast and ugly!"
To make it fast, the crew added an Art Morrison full-tube chassis with Air Ride Technologies 'bags at the corners and a Ford SVO 400-plus-hp small-block with an AOD trans. The truck's design was ugly enough, but Russ felt that a few design changes, like Mini Cooper headlights, would create a somewhat homely bulldog look, but one that might have a little interesting character as well. CCT will show you how this difficult task was accomplished in the following photos.
The highly modified truck is in the paint shop as we're writing this. Painted Dreams has recently added the Lexus Absolute Red to the body panels. We can't wait to see this rascal truck in the Red topcoat and down on its wheels. We promise you'll get to see feature photos as soon as we can get them shot and in our production schedule. For now, check out how the face of this homely hauler was upgraded with modern headlights from the cute Mini Cooper.
The design rendering was a...
The design rendering was a joint venture. Some of the creative ideas were by Just Dream'N while other were from artist Steve Hagan of Victory Illustrations.
Here's the completed redesign...
Here's the completed redesign of the '39 Ford in primer with a new face. Note the addition of an under-fender air dam.
Before the crew at Just Dream'N...
Before the crew at Just Dream'N started working on the fenders to add the Mini Cooper headlights, the center of the Ford oval grille was surgically shortened 2 inches to improve aesthetics and provide a bit more room for the front air dam.
The crew started the project...
The crew started the project by cutting a hole in the original fender sheetmetal large enough to locate the large-diameter and 12-inch-long headlight assembly. They also made initial assessments to ensure the light beam would project onto the roadway.
With the hoodsides and fenders...
With the hoodsides and fenders in position, work began. In order to make some observations about where to add the large oval headlight to the large round fender, many measurements were made. It was decided to position the headlights slightly inboard of the tires for clearance.
A few reference marks were...
A few reference marks were made to ensure the headlight assembly would stay in the same place each time it was located in the fender.
If you look closely at the...
If you look closely at the inside of the large headlight assembly, you'll notice a crescent-shaped gap around the bright trim ring. This gap must be eliminated when the new fender pattern is created from metal.
The headlight was duct-taped...
The headlight was duct-taped securely in place. Then Russ used several pounds of modeling clay to build a new surface around the oval headlight assembly.
Looking forward from the rear...
Looking forward from the rear of the fender, it's possible to see how the modeling clay was sculpted to flow into the original hoodsides and the original fender shape. Remember, the Mini Cooper headlight assembly is 12 inches long under this new shape.
The modeling clay added to...
The modeling clay added to the fender creates a double peak-one from the center of the new headlight and one through the center of the original fender. Aesthetically, the crew was trying to achieve the look of a '37 Ford fender with an integrated headlight.
Looking from the rear, it's...
Looking from the rear, it's possible to see how the double peak was resolved into the original fender shape.
The modeling clay raised the...
The modeling clay raised the surface around the inside half of the headlight where the assembly will be mounted when the new sheetmetal patch is completed.
The clay was examined from...
The clay was examined from every angle until the crew was satisfied that the shape of the fender was as graceful as possible with the marriage of old and new.
Here's one more look at the...
Here's one more look at the modeling clay (from the side) before a plaster mold was created.
The clay was first wet, and...
The clay was first wet, and thin plastic was used to cover the clay and to serve as a mold release.
Only one side of the new surface...
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 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...
It appears as though the two centerlines are the new headlight and the original fender center.
A wood buck was created using...
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...
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...
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,...
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...
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...
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...
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...
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...
Several pieces were joined together to make the new headlight opening for the fender.
As the pieces were created,...
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...
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...
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...
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...
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...
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...
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.