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.
The welded bumper and mounting-bracket...
The welded bumper and mounting-bracket assembly are ready to go to the chrome shop. It will return as a complete unit ready to install and guaranteed to fit the car.
This fellow has been working...
This fellow has been working on the Dynacorn body since the beginning. Here, he patiently works the panels to perfection.
On the other side of the car,...
On the other side of the car, this completed, smooth finish almost jumps out of the photo for us. Notice the perfectly uniform door gaps.
Last-minute touch-ups are...
Last-minute touch-ups are done even as the paint preparation and papering of the car begins. Walking around the car, the painter notices a blemish in the headlight bucket. Any imperfection that stops his eye is addressed.
The papering is nearly finished...
The papering is nearly finished and continues until the skirt around the car is completely sealed against the lift. The repair to the headlight bucket is nearly done.
There are a few items that...
There are a few items that will be shot separately from the car. Since the spray booth is off-site and won't be necessary for a primer coating, this lower front valance panel is nearly ready and will be shot on the stand.
PCL Prep Klean is used to...
PCL Prep Klean is used to remove surface contaminants such as wax, grease, oil, silicone, or tar. Prep Klean also removes adhesives from the surface to be painted.
Here, two workers wipe the...
Here, two workers wipe the Dynacorn Mustang with a clean cloth wetted with Prep Klean. To prevent fish eyes and adhesion problems, every panel must be wiped down completely. If you omit this step, then all bets are off.
The painter goes over the...
The painter goes over the car with compressed air and a tack cloth. A tack cloth shouldn't be pressed on because the tack substance can be wiped off onto the car.
House of Kolor supplied the...
House of Kolor supplied the materials for the Dynacorn Mustang project. Shown here is the two-part primer that will be used to seal the car. Directions must be followed exactly and the product carefully mixed. The material hardens by chemical reaction, not evaporation.
Using a slow, consistent motion,...
Using a slow, consistent motion, the painter lays down a layer of primer onto the car. He starts at the rocker moldings and works his way up.
Here's the completed job....
Here's the completed job. The car will set up overnight, allowing the primer to cure. The Dynacorn project is really coming together, and the next part of our story will be the finished paint job, rumored to be a bright red. We'll continue to cover this interesting project through to completion for the '07 SEMA show.