Miller's 1929 Ford Roadster Pickup - Building the Removable Aluminum Hardtop
This '29 Roadster Showcases Metalworking Techniques from the Masters
February, 2009
On or off, the removable aluminum hardtop is one of the most attention-grabbing design features of Miller's '29 roadster pickup. Laying beneath the stylish upholstery is a story crafted from talent and metal. The hardtop came together during filming for one segment of the RIDES TV show at Miller's Atlanta-area distribution and training center. There, nationally known custom rod fabricator Pat Keating and renowned metalworker Ron Covell joined Miller district managers Wayne Reece (the driving force behind the roadster pickup's development) and Robert Shepard in building the hardtop. Collectively, these four individuals have more than 100 years of fabricating experience. Here, they share some advice any automotive enthusiast can use, from choosing the right metals to tips for getting accurate curves.
 For cutting thin aluminum...  For cutting thin aluminum sheet and bar stock, use a plasma cutter for a clean edge and minimized warping. The result is a narrow cut and is much faster than metal snips, which can sometimes distort the metal.Perfectly straight cuts can be obtained with this simple tip: Clamp a thin piece of straight bar stock onto the sheet metal. The bar stock will serve as a guide for the torch yielding in a straight cut. Here, Ron cuts the strips that are used as the base of the frame using a Spectrum(r) 625. |  Pat and Ron measure the width...  Pat and Ron measure the width of the side and back panels of the car. The measurements allow room for the installation of upholstery after the hardtop is assembled, resulting in even widths that match the frame of the car. |  Using a Dynasty(r) 200 DX,...  Using a Dynasty(r) 200 DX, Wayne TIG welds the corners of the base together as Pat provides downward pressure using the end of a hammer to hold the two pieces tightly together. (And Pat should be wearing gloves to protect his hands from the arc rays.) |
 Pat uses an old metalworking...  Pat uses an old metalworking trick to shape the window. Start by cutting the shape you want out of wood which will be used as a template to wrap the aluminum around. This gives you matching curves every time. |  Aluminum heats up very quickly...  Aluminum heats up very quickly which makes it difficult to perform long welds without burning though or distortion. Creating a 1-in weld every 4 inches takes care of the heat problem. Wayne demonstrates this technique as he welds the side of the window frame. |  The header forms the leading...  The header forms the leading edge of the hardtop that rests above the windshield. A piece of 3003H14 aluminum sheet is cut to the length of the windshield, curved to the desired angel and finally, reinforced. Seen here, Pat, Wayne and Ron check the angle of the header atop a wooden windshield frame. |
 Satisfied with the curve of...  Satisfied with the curve of the header, Ron grinds the edges taking off any burrs that could cause damage once the final upholstery is installed. |  Pat checks to see if the header...  Pat checks to see if the header is perfectly centered by tapping it into place while clamped to the windshield frame. |  Once the header is centered,...  Once the header is centered, Ron welds it to the window frame. |
 Because the curved piece of...  Because the curved piece of aluminum used in the header wouldn't maintain the desired shape on its own, 1/2-in 6061T-6 bar stock is added for stability and support. |  Smaller spacers are welded...  Smaller spacers are welded every few inches as a quick way to add space while saving stock and weight. |  With the spacers clamped into...  With the spacers clamped into place, the header is TIG welded from end to end, resulting in one solid part without any warping in the middle. |
 Next, Ron shows another metalworking...  Next, Ron shows another metalworking technique by using a sandbag and a hammer to lightly bend and form a cap for the end of the header. |  The forming process is truly...  The forming process is truly an art. Knowing that precision is important, Ron checks the shape and size of the cap frequently until it fits. (Over bending is not desired and hard to fix). |  After the right shape is crafted,...  After the right shape is crafted, the cap is TIG welded into place. Because the cap will be upholstered, Ron grinds the weld making for one seamless curve of metal. |
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