Oldsmobile Rear Bumper Fab and Floor Pans

(ANNOUNCER)>> TODAY ON MUSCLE CAR, WE'LL SHOW YOU HOW TO CUSTOMIZE A REAR BUMPER TO GIVE IT A ONE OF A KIND LOOK WITH AN AERODYNAMIC EDGE.

LATER THE GUYS DO MOTOR MOCK UP AND SLIP SOME NEW FLOORS IN THE OLDS. AND FLASHBACK TAKES A LOOK AT A FANCY FORD.

(TOMMY)>> HEY Y'ALL, WELCOME TO MUSCLE CAR. TODAY WE'RE GONNA GET UP CLOSE AND PERSONAL WITH OUR OLDSMOBILE HURST TRIBUTE CAR. I'VE GOT SOME CUSTOM BUMPER MODS I'M GONNA THROW AT THE BACK SIDE OF HER, AND THEN WE'RE GONNA LOOK AT POKING IN SOME FRONT FLOOR PANS. BUT FIRST THINGS FIRST, THIS BACK BUMPER'S GOT SOME NICE STYLE LINES TO IT AND IT WAS A GOOD COMPLIMENT TO THE ORIGINAL LOOK OF THE CAR, BUT WE'RE SLOWLY CHANGING THE LANDSCAPE OF THE SHEET METAL. I'VE GOT SOME IDEAS TO BRING THIS THING UP TO SPEED WITH THE REST OF THE MODIFICATIONS THAT WE'VE DONE TO THE CAR, BUT IT'S ALL GONNA START WITH GETTING IT ACQUAINTED WITH SOME MASKING TAPE. WE TOOK THIS THING OVER TO OUR BUDDIES AT ADVANCE PLATING TO GET THE STRIPPED OFF OF IT. THAT WAY IT MAKES IT A HECK OF A LOT EASIER TO GET PAINT, PRIMER, FILLER, WHATEVER TO STICK TO IT. I'M MEASURING BECAUSE I WANT TO INCORPORATE A REAR DIFFUSER ON THIS THING, AND I'M MAKING A COUPLE OF MARKS TO SEE WHAT WILL WORK AND WHAT WON'T. I ALWAYS LIKE TO SQUARE OUT MY DESIGNS, MORE OR LESS AT 90. A LOT EASIER TO GET THOSE ACCURATE.

THEN COME BACK, SHAPE OUT WHAT YOU LIKE, THEN JUST CUT AND PULL THE TAPE OUT AND AWAY.

I LIKE TO USE THAT WIDER TAPE WHEN LAYING STUFF OUT BECAUSE IT'S A LITTLE MORE STABLE. BUT WHENEVER YOU START DOING THE RADIUS, THIS THINNER STUFF IS THE WAY TO GO.

ALSO THERE'S NOTHING WRONG WITH USING A TEMPLATE WITH WHATEVER YOU CAN FIND AROUND THE SHOP THAT'S GOT A GOOD RADIUS TO IT. AFTER LAYING OUT WHAT I THOUGHT I WANTED, I DON'T LIKE IT. THE HEIGHT OF IT IS A LITTLE BIT TOO HIGH BECAUSE OF THE BODY LINE THAT'S FACTORY STAMPED INTO THE BUMPER. I NEED TO BRING IT DOWN PROBABLY, IT LOOKS LIKE ABOUT AN INCH AND A HALF, TWO INCHES. SO THE TAPE IS DEFINITELY THE WAY TO GO BECAUSE IF YOU WERE TO CUT INTO THIS THING, YOU WOULD HAVE DONE MESSED UP. SOMETIMES YOU'VE GOT TO USE THAT OLD CALIBRATED EYE BALL. I'LL REPEAT THE STEPS THAT I TOOK THE FIRST TIME TO GET MY CORNERS LAID IN. NOW THAT I'VE DETERMINED THE AMOUNT I WANT TO CUT OFF THE LOWER SECTION, I'M READY TO LET SOME SPARKS FLY. BUT BEFORE I CUT IT, I'M GONNA CUT OUT THIS LICENSE PLATE RECESS AND MOVE IT UP JUST A LITTLE BIT TO HELP THE LOOKS.

LET ME SHOW YOU SOMETHING. IT'S A GOOD IDEA TO USE A MARKER AND RUN IT ALONG THE EDGE WHERE YOU GONNA CUT AT, ESPECIALLY WHEN YOU'RE USING TAPE, CAUSE WHENEVER YOU'RE USING A GRINDER OR SOMETHING, THE METAL GETS HOT AND SOMETIMES THE TAPE BLOWS OFF. WITH A MARK ON IT YOU STILL KNOW WHERE

YOU'VE GOT TO CUT AT. THIS BUMPER IS MADE WITH SOME SERIOUS METAL.

SO I'VE ADAPTED THIS MATCO ELECTRIC GRINDER TO CARRY ONE OF OUR INDUSTRIAL DEPOT CUTTING WHEELS. THE GRIND HAS A LOT MORE UMPH THAN THE AIR TOOLS THAT YOU TYPICALLY USE. I'LL USE A FILE AND AIR GRINDER TO GROUND OFF THE BURRS AND BEVEL THE EDGE. THEN IT'S JUST A MATTER OF TACKING IN OUR PANEL.

FOR THE CORNERS I ALSO GRAB MY AIR SAW BECAUSE IT HAS NO TROUBLE MAKING THOSE TIGHT TURNS. A LITTLE MORE TAPE AND SOME MORE QUALITY TIME THE AIR SAW, WE'LL HAVE THE BOTTOM OF OUR PLATE PREPPED FOR THE NEXT STEP.

WELL WE'RE PRETTY MUCH DONE CUTTING METAL OUT AND WE'RE AT A POINT TO START PUTTING SOME IN.

(ANNOUNCER)>> AFTER THE BREAK TOMMY PUTS THE PUZZLE PIECES INTO PLACE AS THE OLDSMOBILE'S BUMPER COMES BACK TOGETHER. THEN GOTTA MAKE ROOM FOR A BIG OLE TRANNY? SEE HOW TO MAKE A RELIEF CUT IN A TRANNY TUNNEL.

(TOMMY)>> WELL WE'RE WELL ON OUR WAY TO HAVING US A CUSTOM REAR BUMPER FOR THE BACK SIDE OF OUR HURST OLDS TRIBUTE CAR, AND I'VE CUT A GIANT HOLE IN THE BACK SIDE OF IT AND I'VE ALREADY STARTED CUTTING THE PIECES THAT I'M GONNA USE TO REBUILD IT. AND WHEN WE'RE ALL SAID AND DONE, WE'RE GONNA HAVE US

A PIECE OF ART THAT'S ONE OF A KIND. NOW I COULD HAVE MADE THIS INSERT ONE GIANT PIECE, BUT I DECIDED TO MAKE IT IN SECTIONS. THAT WAY IT MAKES EASIER TO MANAGE.

WHAT I LIKE TO DO IS DO THE STRAIGHT SECTIONS FIRST AND THEN COME BACK AND DO THE RADIUS.

WHEN I MADE THIS NEXT PIECE THAT I'M PUTTING IN HERE, I USED OUR TIN SMITH METAL BREAK TO PUT SOME BENDS IN IT. TO MAKE A GRADUAL ANGLE, I BENT THE METAL BY HAND INSTEAD OF USING THE LEVER. NOW YOU CAN MAKE SOMETHING SIMILAR TO THIS USING A VICE, LET ME SHOW YOU. IT'S REALLY PRETTY SIMPLE, JUST STICK THE METAL

INTO A VICE AND DO YOUR BENDS BY HAND. OR USE A HAMMER TO GRADUALLY WORK IT OVER. NOW IF YOU'RE DOING A LARGER PIECE YOU MAY HAVE TO CUT IT INTO A SMALLER SECTION TO GET IT TO FIT INTO A VICE.

BUT THE END RESULT, IF YOU TAKE YOUR TIME, IT'LL BE PRETTY MUCH THE SAME. MAKE SURE YOU'RE USING THE RIGHT METALS FOR THE JOB THAT YOU'RE WORKING ON. THIS BUMPER'S MADE OF THICKER METAL THAN THE BODY PANELS, AND I'M USING 10 GAUGE STEEL CAUSE IT MATCHES UP TO THE BUMPER PRETTY WELL. A CARDBOARD TEMPLATE HELPS ME TO NOT WASTE STEEL. AND ONCE I'VE GOT IT CUT TO SHAPE, I'LL REPRODUCE IT IN METAL AND TACK IT IN. A DIE GRINDER WITH A ROTARY FILE ON THE END IT WILL FINISH UP OUR INSIDE CORNER. THIS LITTLE RECESS AROUND THE LICENSE PLATE HOLE NEEDED TO HAVE A PATCH PUT IN IT. SO I MADE ME A TEMPLATE USING A PIECE OF CARDBOARD, TRANSFERRED IT TO A PIECE OF STEEL, IT SHOULD WORK RATHER NICE TO FILL THE HOLE. WHAT I'LL DO IS MAKE SURE THAT I'VE GOT THIS PIECE CARVED OUT THE WAY I WANT IT. THEN DRAW A LINE AROUND IT SO THAT I CAN CUT THE METAL OUT THAT WOULD BE HANGING BEHIND IT. BY NOT DOING THIS WHAT IT CREATES IS A POCKET FOR MOISTURE, DIRT, DEBRIS TO COLLECT, AND THEN YOU'VE GOT YOURSELF A RUST FARM, AND THAT'S WHAT YOU DON'T WANT.

ONCE I USE THE AIR SAW TO GET RID OF ALL THE UNWANTED METAL, I CAN TACK IN MY PATCH AND CALL IT GOOD. WHEN WORKING WITH INTRICATE PIECES LIKE WE ARE, A MAGNET LIKE THIS ONE WE GOT FROM MATCO CAN MAKE

THIS JOB A LOT EASIER.

NO MORE TACKING IS NECESSARY. IT'S TIME TO BURN THIS DUDE IN. THEN I'M GONNA LOVE UP ON IT WITH A GRINDER FOR A LITTLE WHILE. THE SMOOTHER YOU GET IT NOW, THE LESS BODY WORK YOU'LL HAVE TO DO LATER. WELL I GOT ALL MY GRINDING WRAPPED UP AND I DON'T THINK

IT TURNED OUT HALF BAD. THIS MOD IS SIMILAR TO THE DIFFUSERS THAT YOU SEE ON A LOT OF RACE CARS, WHICH REDUCE AERODYNAMIC DRAG, ALONG WITH LOOKING JUST PLAIN COOL. WITH ALL THAT TOOK CARE OF, WE'RE ONE STEP CLOSER TO TAKING OUR OLDS DOWN THE ROAD. BUT Y'ALL KNOW HOW THAT GOES, WE'VE STILL GOT A LONG WAYS TO GO.

(ANNOUNCER)>> STILL AHEAD WE TAKE A LOOK A CHERRY PIECE OF DETROIT IRON, AND LATER WE'RE BACK IN THE STUDIO WITH THE OLDS WHERE THE GUYS DO SOME SERIOUS FLOOR SURGERY, STICK AROUND.

(ANNOUNCER)>> TODAY'S FLASHBACK, A 1967 FORD FAIRLANE GTA.

(RICK)>> THERE IS NOTHING LIKE THE FEELING OF DRIVING A CAR

THAT YOU BUILT YOURSELF. BOB CARTER HAS BUILT MANY FORD'S IN HIS LIFETIME. HE SPENT OVER THREE DECADES ON THE ASSEMBLY LINES OF DETROIT BUILDING SOME OF THE FINEST BLUE OVAL CARS. THIS PRISTINE '67 FAIRLANE GTA IS HIS PRIZED POSSESSION, AND HE DOESN'T MIND TAKING IT OUT FOR A SPIN WITH THE TOP DOWN, EVEN IN THE DEAD OF WINTER.

(BOB)>> I LIKE TO DRIVE CAUSE, YOU KNOW, IT HAS QUITE A LOT OF ZIP TO IT, AND GET A LOT OF ATTENTION FROM PEOPLE THAT REALLY DON'T KNOW, YOU KNOW, HOW OLD THE CAR OR WHAT KIND IT IS.

(RICK)>> THE FAIRLANE FIRST HIT THE ROAD IN 1955 AS A FULL SIZE CAR, BUT SHRUNK TO A MID SIZE IN '62, FILLING THE GAP BETWEEN THE COMPACT FALCON AND THE MASSIVE GALAXY. FORD WANTED TO TAKE ON THE MIGHTY GTO. SO IN '66 THEY REDESIGNED THE FAIRLANE ENLARGING THE ENGINE BAY AND DROPPING IN A BIG BLOCK VEIGHT FOR THE FIRST TIME. THIS '67 HAS THE 390 FOUR BARREL, WHICH COULD BELT OUT 320 HORSES.

IT USES A CAST IRON MID RISE MANIFOLD AND FEATURES THE SAME HOT CAM AND VALVETRAIN AS THE 428 COBRAJET. FAIRLANE'S CAME IN A WIDE RANGE OF PACKAGES, INCLUDING THE 500, THE XL, THE GT, AND THE GTA. THE GTA WAS VIRTUALLY THE SAME AS THE GT EXCEPT THE "A" MEANT THAT IT WAS AN AUTOMATIC. THE SELECT SHIFT CRUISEOMATIC GAVE YOU THE BEST OF BOTH WORLDS. ( )>> SOME PEOPLE LIKE AUTOMATIC TRANSMISSIONS.

(RICK)>> IT FUNCTIONED LIKE AN ORDINARY AUTOMATIC FOR EVERYDAY DRIVING, OR FOR EXTRA CONTROL YOU COULD USE IT LIKE A THREE SPEED AND SHIFT IT FROM FIRST, TO SECOND, TO DRIVE.

GTA'S CAME WITH POWER FRONT DISC BRAKES, BLACKED OUT GRILL TREATMENT, WIDE OVAL TIRES WITH DELUXE WHEEL COVERS, BUCKET SEATS, AND PLENTY OF BADGES AND STRIPES. POWER DOMES REPLACED HOOD LOUVERS THIS YEAR AND HAD INTEGRATED TURN SIGNALS. A 289 VEIGHT WAS STANDARD WITH TWO OR FOUR BARREL 390 AS AN ADDED OPTION. '67'S GOT A SLIGHT MAKEOVER FROM THE '66 MODELS. THE GRILL GOT THREE VERTICAL CROSS BARS AND A CREST WAS ADDED IN THE CENTER AS WELL AS ON THE REAR. TAIL LIGHTS ALSO GOT A NEW STACK DESIGN TO MATCH THE HEADLIGHTS. TO LOWER THE TOP, FIRST HE HAD TO UNZIP THE GLASS REAR WINDOW AND LAY THEM FLAT. THEN YOU LET THE CAR DO THE REST. THE GTA HELD ITS OWN AGAINST MORE POWERFUL MUSCLE CARS LIKE THE FOURFOURTWO AND CHEVELLE, BUT COULDN'T QUITE TOP THE GTO, UNLESS THAT TIGER WAS AN AUTOMATIC. PRODUCTION FELL BY 40 PERCENT IN '67 TO A TOTAL OF JUST 20,787. THIS WAS THE SECOND AND FINAL YEAR FOR THE FAIRLANE GTA WITH THE TORINO GT REPLACING IT IN '68. THE GTA'S LIMITED PRODUCTION LIFE AND STATUS AS THE FIRST OF THE BIG BLOCK FAIRLANES MAKE IT HIGHLY COLLECTIBLE TODAY.

THERE'S NO DOUBT THIS CAR IS CLOSE TO BOB'S HEART.

(BOB)>> I SUPPOSE AFTER SPENDING ALMOST 30 YEARS AT FORD, YOU GET A LITTLE FORD IN YOUR BLOOD.

(ANNOUNCER)>> COMING UP, WINCHING A MODERN MOTOR AND TRANSMISSION INTO AN OLD TIMEY AUTOMOBILE!

(TOMMY)>> WE'RE JUMPING OVER HERE TO GET SOME WORK DONE ON OUR OLDSMOBILE. TODAY WE WANT TO GET OUR MOTOR AND TRANSMISSION MOCKED UP TO SEE WHAT WE'VE GOT TO DO TO OUR FLOOR PAN. THIS ISN'T EXACTLY THE TRANSMISSION WE'RE GONNA BE RUNNING. WE BORROWED THIS ONE FROM HORSEPOWER, BUT IT'S CLOSE ENOUGH WE CAN GET BY.

(RICK)>> NOW FROM THE FACTORY, OUR OLDS ROLLED OFF THE ASSEMBLY LINE WITH AN AUTOMATIC AND THREE GEARS, BUT WE'RE GONNA BE DOUBLING THAT TO SIX. PLUS WE'RE GONNA ADD A THIRD PEDAL. NOW THE SHEER SIZE OF THAT LATE MODEL TRANSMISSION MEANS THAT WE'RE GONNA HAVE TO DO SOME MODIFICATIONS TO THE FLOOR. WELL AS LONG AS WE'RE THERE, WE MIGHT AS WELL REPAIR ALL THIS RUST DAMAGE.

(TOMMY)>> NOT A BAD IDEA TO GO AHEAD AND PULL THE SHIFTER SO YOU DON'T HAVE WRESTLE IT INTO THE TUNNEL.

(RICK)>> ALRIGHT, I'M GONNA COVER THIS UP BECAUSE EVEN THOUGH THIS IS A MOCK UP TRANSMISSION, IT'S STILL A GOOD TRANSMISSION. I DON'T WANT A BUNCH OF JUNK FALLING DOWN INSIDE OF IT.

(TOMMY)>> A LITTLE MORE!

MOTOR MOUNTS BOLTED, WE'LL SLIDE A JACK UNDER THE TRANNY AND SEE HOW HIGH IT CAN RIDE. OKAY, FLOOR'S COMING UP.

(RICK)>> WOW, THAT'S IT HUH? WELL FROM WHAT I CAN SEE, I THINK WE MAY HAVE LUCKED OUT HERE. LOOKS LIKE ALL WE HAVE TO DO IS MAINLY CUT OUT THIS LITTLE LOW SPOT RIGHT THROUGH HERE AND I THINK THAT'LL LET THE TRANSMISSION COME UP AND RELAX A LITTLE BIT. SO I DON'T KNOW, WE'LL SEE. HOPEFULLY WE GOT LUCKY.

(TOMMY)>> NOW WHEN YOU'RE RELIEF CUTTING IT'S A GOOD IDEA TO START SMALL AND KEEP TRIMMING UNTIL THE HOLE IS BIG ENOUGH.

THAT WAY YOU CAN KEEP A CLOSE EYE ON WHAT YOU'RE CUTTING AND PREVENT HAVING TO GO BACK AND REPLACE METAL THAT

NEVER HAD TO COME OUT.

(RICK)>> HUH, I'LL BE DARNED, WE GAINED QUITE A BIT OF SPACE THERE. WELL THAT WASN'T NEAR THE HASSLE THAT WE WERE EXPECTING. I MEAN I'VE HEARD HORROR STORIES OF GUYS DANG NEAR

CUTTING CARS IN HALF TO GET THESE TRANSMISSIONS MOUNTED. BUT HEY, WE'RE SITTING AT THE RIGHT HEIGHT AND WE'RE READY TO MOVE FORWARD.

(TOMMY)>> SO NOW WE NEED TO FIGURE OUT WHERE WE WANT TO CUT OUR FLOOR PANS.

WE GOT OUR REPLACEMENT PANELS FROM YEAR ONE. THEY OFFER A FULL FLOOR PAN, BUT LUCKILY FOR US ONLY THE FRONTS WERE BAD. SO WE JUST OPTED FOR THE PARTIAL REPLACEMENT PANEL. THERE'S A FEW THINGS TO CONSIDER WHEN

INSTALLING A PATCH. YOU DON'T REALLY HAVE TO USE THE ENTIRE PANEL. MY PLAN IS TO CUT RIGHT ACROSS THIS LINE BECAUSE IT'S A LITTLE EASIER TO BLEND IN YOUR METAL WORK LIKE IT'S NOT EVEN EVER BEEN REPAIRED. NOW THIS PANEL ORIGINALLY IS WELDED UNDER THE ROCKER AND TO THE INNER ROCKER, BUT DOING IT MY WAY SAVES US A LITTLE WORK.

NOW I'M GONNA USE AN AIR SAW. YOU DON'T REALLY HAVE TO, YOU COULD USE A CUT OFF WHEEL OR A PLASMA, BUT THE PROBLEM WITH A PLASMA IS THERE'S ALWAYS THE CHANCE THAT YOU'RE GONNA HAVE DRESS THE STEEL BECAUSE OF THE SLAG. WITH THE AIR SAW, YOU DON'T HAVE TO DO THAT. BUT IT'S VERY LOUD! [ air saw cutting ]

(TOMMY)>> ANOTHER THING TO PAY ATTENTION TO IS YOUR INNER FLOOR BRACES. YOU CAN SEE THE SPOT WELDS WHERE IT'S ATTACHED TO THE FLOOR PAN. IF YOU JUST CUT STRAIGHT ACROSS YOU DAMAGE THE FLOOR SUPPORTS AND YOU HAVE TO MAKE THAT REPAIR. NOW USING A GRINDER WITH A CUT OFF WHEEL, I'M GONNA SLICE

THROUGH JUST THE FIRST LAYER. NOW ALL WE'VE GOT TO DO IS DRILL OUT SOME SPOT WELDS,

THIS PANEL WILL BE OUT. THIS IS ONE OF THOSE TIMES THAT THERE'S A

RIGHT TOOL FOR THE JOB. I'M GONNA USE A MATCO SPOT WELD CUTTER. THIS MAKES WORKING ON A PANEL LIKE THIS A WHOLE LOT EASIER. THIS THING IS BASICALLY A TINY HOLE SAW.

WHAT IT ALLOWS YOU TO DO IS CUT THROUGH ONE PANEL WITHOUT DAMAGING THE METAL UNDERNEATH. WITH THAT EIGHTH INCH BIG WHAT I DID IS I GAVE THIS THING A SEAT FOR IT TO KINDA RIDE IN. THEN YOU PUT IT BACK ON THERE, SQUISH IT DOWN,

PULL THE TRIGGER.

WHEN YOU GO TO CUT OUT YOUR NEW PANEL, YOU WANT TO TRIM IT A LITTLE BIT LARGER THAN THE ORIGINAL. IT GIVES YOU A LITTLE EXTRA ROOM WHEN YOU GO TO INSTALL IT. THE REASON THAT YOU WANT TO LEAVE THAT EXTRA OVER HANG IS THAT IT'S ALWAYS EASIER TO COME BACK AND TRIM A LITTLE MORE OFF, BUT IT'S A WHOLE OTHER STORY WHEN YOU'VE GOT TO ADD IT BACK IN.

A LITTLE EXTRA TIME DURING FITMENT CAN SAVE YOU A LOT

OF WORK ON THE BACK END. SO MAKE SURE YOU DO IT RIGHT THE FIRST TIME. I GOT THE PATCH MOSTLY FIT, SO I'M GONNA GO AHEAD

AND START WELDING IT IN.

THAT WAY IT DOESN'T WIGGLE AROUND NEARLY AS MUCH AS I FINISH THE TRIM PART OF IT.

A COUPLE OF KLICOS ALSO HELP HOLD HER STEADY. WITH IT TACKED INTO PLACE, I'M GONNA TAKE MY SAW AND RUN BACK THROUGH THIS JOINT. WHAT THAT DOES IS THAT OPENS IT UP JUST IN CASE THE TWO PANELS ARE PUSHING AGAINST EACH OTHER. ALSO THAT GIVES ME A LITTLE BIT OF ROOM FOR A GOOD BUTT WELD.

WELL SHE'S ALL TACKED IN, ALL IT NEEDS NOW IS A LITTLE BIT OF WELDING AND GRINDING AND THAT'LL BE ALL SHE WROTE. THE OTHER SIDE IS PRETTY MUCH THE SAME AND I'M GONNA LET

RICK HAVE A STAB AT IT.

(RICK)>> THANKS, WELL THE GOOD NEWS IS THIS SIDE AIN'T MUCH WORSE OFF THAN THE FIRST SIDE WAS. THE BAD NEWS IS WE'RE ALL OUT OF TV TIME FOR THE WEEK. IF YOU GUYS HAVE ANY QUESTIONS ABOUT ANYTHING YOU SAW ON THE SHOW TODAY, YOU CAN CHECK IT ALL OUT AT POWERBLOCK TV DOT COM. BUT UNTIL NEXT TIME, WE'RE OUTTA HERE.