When we last left our Dynacorn fastback project at Autoworks International, a new suspension from Revelation Racing Supply had just been installed ("Shell Game," Sept. '07). Both the front and rear suspension kits include disc brakes using PBR calipers. The coil-over front suspension and three-link rear were both bolt-on installations, giving our rolling shell state-of-the-art underpinnings. The bodywork began while the car was up on the lift as some smaller body panels were welded together. The rear valance panel was welded to the lower rear quarters, with additional work to be done in the body shop.
Although the Dynacorn Mustang replacement body shell arrived looking good in a coat of primer and ready for finishing, it was decided to have the body mediablasted. This procedure strips off the original primer so that a two-part primer can be applied, thus eliminating any variables and assuring product continuity during the painting process. If there are any problems with the paint down the line, there's no mystery component to consider.
The finishing work is already underway at the Autoworks body shop, with the last of the bodywork winding down. Special attention is paid to accurate panel fitment. Even though the new body is essentially pristine when it arrives, for this high-end show-car build, the panels require finish work prior to priming and painting. Expectations are high on this project-every panel must be smoothed to perfection and all door and fender gaps made uniform.
Once preparation is complete, the House of Kolor two-part KD2000 Direct to Metal Primer will be applied. There's still a lot of work to be done before that can happen, so let's take a look into the busy body shop and see what the crew is up to.
When in doubt, a skim coat...
When in doubt, a skim coat of body filler gives a uniform surface to begin work. Large panels such as this trunk lid or doorskins require long and smooth surfaces, and a skim coat can eliminate slight waves in the sheetmetal. When the coat is sanded down, the panel will have the appearance of a dalmatian, with various filler tones and primer colors spotting through. The hood has a fiberglass outer shell and didn't require a skim coat, just sanding.
On the ground, our man cleans...
On the ground, our man cleans up everything and smooths the filled holes, rounding the corners where the quarter joins the valance panel. He also has a good fit on the quarter-panel extensions.
Every part of the body is...
Every part of the body is tested for proper fit before the paint. Here, a bumper and fender extension is test-fitted. Autoworks has a nice trick for the installation of the bumpers, as we shall soon see.
The entire front bumper and...
The entire front bumper and bracket assembly will be chromed as a single unit, so it doesn't matter that the welding heat comes through and spoils the original chrome plating.
With the Dynacorn Mustang...
With the Dynacorn Mustang in the body shop, there are often several people working on it at the same time. Here, the bumpers are being welded to their brackets after correct fitment is achieved. On the passenger side, the body panel becomes level with the doorskin.
At the other end of the bumper,...
At the other end of the bumper, the mounting hardware is welded also. The result is one complete and extremely rigid assembly that will fit the car when the time comes.