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w55_01
The white arrows point to the outer flange of the rear body that was fabricated using the bottom of the trunk lid as a guide. This flange serves as a starting point of the outer body that will continue down to the bottom of the trunk tool tray.
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w55_02
Here, a close-up shot showing the left side, with the trunk open. Most of the inner trunk gutter (see arrow) was salvaged but a missing section (in the circle) had to be made on both right and left sides, in order to attach the gutter.
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w55_03
This shot of the right side shows the missing section of inner gutter welded in place. (Circle) Now that both the inner gutter and outer flange have been secured to the rest of the body, the outer body skin can be formed.
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w55_04
The white shape drawn on the photo shows the missing outer area that will be fabricated on both left and right sides. A third center piece will also need to be made to join the right and left halves.
The white arrow points to the lower body flange that serves as the bottom of the outer body and inner tool tray. The lower flange was made extra long. It will be trimmed much shorter when the rear body is complete.
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w55_05
The outer skin patches are mostly formed on the English wheel.
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w55_06
Rough test clamping of the left side outer body patch. Many test fittings like this are made to determine the exact final shape needed.
Because the outer pieces determine the final shape of the inner tool tray, they must be formed before the inner tool tray can be finished. Only then can the outer pieces be welded on.
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w55_07
Rough test clamping of the right side outer body patch.
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w55_08
The white arrow points to the inner tool tray box section that has been formed and welded in on the left side. Note the curved shape follows the general shape of the outer body.
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w55_09
Right side inner box section completed. Now that the inner boxes are finished, it's time to start fitting trimming and welding on the outer body sections.
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w55_10
Left side trimmed, fit and tack welded in place.
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w55_11
Right side trimmed, fit and tack welded in place.
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w55_12
Both right and left pieces tack welded. Once the missing center section is fabricated, all pieces can be completely welded together and metal finished, None of these weld seams will be present when we arrive at the painting stage.
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w55_13
Fabricated center section fit and tack welded in place.
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w55_14
Angle view of the rear body shows the contours of the sheet metal. Next, is to finish welding all the pieces together with a continuous gas weld.
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w55_15
Pieces all gas welded together with continuous Henrob torch welds. The next step will be to grind all the welds flush inside and out. Then with the hammer, dolly and file, smooth any low or high spots.
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