Vintage Woodworks has always been located about as far away from an ocean coast as you can get. First it was tiny Iola, Wis., then on to a new home in Lu Luz, N.M. Surrounded by wood-bodied sedans and convertibles with the Beach Boys blasting on the radio, the business is the kind of place a woodie owner can drop off the chassis and cowl of his or her car and pick up a show-stopping, road-ready winner. And many woodie owners from the coasts and everywhere between and beyond do exactly that.
The shop’s proprietors, Dennis and Kathy Bickford, can restore nearly any type of woodie, but their business evolved during the more than 30 years the shop has been helping owners drive to Surf City, and the business now specializes in Chrysler Town and Country models. Along with restoring and rebuilding wood components and re-upholstering tops and interiors, the couple has built an incredible inventory of used and new reproduction parts for the unique vehicles. The focus of this article is just one of the parts that Vintage Woodworks reproduces: the wood-and-metal inserts that flush out the white ash framework of 1946-’48 Town and Country convertibles.
According to Dennis Bickford, there are 12 such panels on a Town and Country convertible, and as the supply of nicer cars has dried up, his customers have begun restoring rougher cars. Some of the cars that enter Vintage Woodworks were once considered parts cars, and they often have missing or damaged panels. Of the 12 panels, half are flat and the other half have a compound shape. All were originally metal panels with a wood veneer covering until mid-1947, when Chrysler Corp. switched to a DiNoc panel with a simulated wood pattern covering the metal panels. Nearly all of Bickford’s customers have their cars restored with wood veneer panels, regardless of when they were built, because “[Real] wood gives life to the car,” Bickford said.
To replace missing panels, Bickford uses metal cut to fit, and for those panels with a compound surface, he has them formed with an English wheel. The only replacement panels he offers that are not remade in metal are the upper door panels, which have extremely complicated curves. For these, he has fiberglass panels molded in the original shape.
Before the panel is prepped, Bickford places the pre-cut veneer on top of the panel in a vacuum press so the flat veneer begins to conform to the curved panel’s shape. The press applies 2,000 pounds per square inch of pressure to help mate the veneer to the panel. During this step, he marks the location of the metal panel on the veneer so the two parts can be mated in exactly the same position in a later step.
Sanding the metal panels with a 36-grit disk removes any traces of old material on used panels and, on both new and used panels, creates a surface that will allow epoxy to adhere.
To show how these panels are covered with veneer, Bickford used the upper trunk panel on a 1946-’48 Town and Country convertible as an example. These upper trunk panels are among those with a compound curve. His process for creating these panels is different than that of Chrysler Corp., which originally glued the veneer to the flat metal panels and, after the glue dried, stamped the panels to shape. Bickford credits this process with premature failure, so he has the panel shaped, then applies the veneer.
To start, Bickford places the veneer panel, which is cut slightly larger than the metal panel, on top of the metal panel and inserts the components into a vacuum press for 24 hours. By doing so, he slowly introduces the wood veneer to the compound shape it will need to adopt from the metal panel, thus preventing wrinkles in the veneer. The veneer and metal panel are not yet glued together in this step.
After the veneer has begun to take the shape of the curved metal panel, Bickford removes the veneer and metal panel from the vacuum press and prepares the metal panel for the epoxy that will bind the metal panel and veneer. A 36-grit blue sanding disk is spun over the already-shaped metal panel to rough its surface to help the epoxy adhere.
Once the panel has been sanded to an appropriate texture, Bickford applies acetone to remove grease, silica from the disk and any other contaminants that could prevent epoxy from adhering to the metal panel. Three acetone rinses are liberally applied to ensure a clean surface.
Acetone is liberally poured onto the steel panel three times to eliminate any contaminants from the panel’s surface. The presence of any contaminants can prevent the epoxy from adhering.
Once the metal panel is clean, Bickford mixes his two-part marine epoxy using a scale to ensure he has the exact mix dictated by the epoxy’s manufacturer. With the epoxy mixed, he uses a single-use sponge roller to roll the epoxy onto the metal panel. According to Bickford, brushes will not evenly apply the epoxy to the level required.
After the epoxy has been applied to the metal panel, the veneer can be laid over the top. To hold the two parts together, Bickford tapes the pieces together at the top and the bottom, then inserts them in the vacuum press for 24 hours.
When the panels come out of the vacuum press, signs of the epoxy coming through the wood veneer are visible as little specks. Rather than sand these specks off, Bickford lightly glides a cabinet scraper across the top of the veneer to remove the signs of the epoxy. Once they are smooth and free of specks, the panels can be finished.
Bickford strictly follows the mixing directions on the epoxy manufacturer’s label using a scale to ensure the proper ratio.
A disposable roller is used to evenly apply the epoxy to the metal panel. Brushes do not spread the epoxy evenly enough, and the rollers are only good for one use after they have been used to apply the epoxy.
Bickford uses a powder analine dye to stain the surface of the panel, because it’s clear with more particles per volume than an oil-based dye, thus giving a clearer view of the wood and its grain. Once the dye has penetrated the veneer and dried, Bickford applies a West System epoxy, per the manufacturer’s instructions, to help bond the next coat. When the West System epoxy has dried, a final finishing using a varnish or urethane is applied.
The veneer is ready to be applied to the epoxy-covered metal panel for the final vacuum-pressing step. Bickford follows the marks he left on the veneer the first time it was placed in the vacuum press to ensure the veneer is placed in the same spot as the first time the veneer and panel were pressed. Tape keeps the veneer and metal panel in place while in the press.
After coming out of the press, the veneer and metal panel are mated as one. Since the veneer was cut larger than the panel, the excess veneer can now be carefully shaved off the panel.
After it comes out of the press, the veneer is spotted with epoxy that has been pressed through the wood. Bickford uses a cabinet scraper to lightly remove the specks.
For Bickford, an accomplished woodworker and restorer who has made dozens of panel sets, the entire process takes about 10 hours over one week. The results of Bickford’s process can be seen on the best woodies at concours fields and other judged show fields around the world.
MORE INFO:
Vintage Woodworks
Wood-bodied car restoration specialists, used and reproduction part source for 1942-‘50 Chrysler Corp. products
Dennis and Kathy Bickford
P.O. Box 1132, La Luz NM 88337
575-443-1160