This automotive restoration project began in June 2010, with the client’s sights set on putting it on display in Pebble Beach. This 1960 Ferrari 250 GT Pininfaria Cabriolet (PF Cab) was stored for 30 years in Arizona before being purchased by the current owner. Ferraris during this time were hand built by Italian coach manufacturers and the engines were also hand built by Ferrari. The 250 GT series was built for the customer who wanted a street legal car that he could also take to the race track. Of course not everyone raced their Ferraris, some customers just wanted the incredible power and beautiful styling of the 250 GT. Pininfarina is still in business and still making concept cars and prototypes for major companies around the world.

After the Ferrari 250 GT PF Cab was taken apart and criticized by the media, I started repairing and rebuilding the bodywork to its original factory condition.

This client was especially concerned with making the reconstruction perfectly symmetrical. I had an idea, born from my experience working in the prototype industry: to build a box with a measuring system to help in the construction of the vehicle. The photos below are a brief sample of the posts to follow.
The first part of this post covers a measuring device that we designed and built especially for this Ferrari PF Cab and the second part explains how it was used to rebuild the taillight area.

The goal of the gauge box is to determine if a car body was built at right angles to the chassis and if it is symmetrical from side to side. Before we delve into body measurement, remember that this is a 1960s hand-built Ferrari body, so tight tolerances are not expected. The idea is that the body and chassis of the Ferrari PF Cab sit on a central line within a three-dimensional steel-framed box. The perimeter of the box acts as a measurement datum so that measurements from the box to the Ferrari PF cockpit can be taken on the left and right sides and then compared to check symmetry.

The three-dimensional box is divided into 3 planes that represent length, depth and height. In each shaft there are 1/2″ machined holes 200mm apart, these holes are locations for the gauge stations. A line runs down the center of the case and the center of the chassis is aligned with a custom body mount. The center line only runs lengthwise, as the body is only symmetrical in one direction. The body is divided into a grid, with the help of a laser, and numbered for easy registration.

These were the most important findings for this Ferrari PF Cab:

1. Right headlight housing is 10mm further forward than left headlight

2. the body style line is 6mm higher on the right side than on the left side

3. The entire rear of the car is flipped to the right hand side 50mm from the rear of the doors to the rear of the Ferrari. Not because of accident/damage, but because of how the car was built.

4. left taillight housing beak tilts in 8mm

After discussing the above findings with the customer, the first issues addressed were the left tail light issue. We will now show the step-by-step rebuilding and fabrication of the light housing. Why rebuild this area? At first glance, the sheet metal case clearly looked as if the top was tilted inward, and secondly, the case was too large for the slight bezel, which formed the appearance of a step. For proper appearance, the bevel surface must be flush with the paint surface. As part of the “measuring box” process, we recorded results showing that the top of the case was 5mm to the right of center. To fix both of these problems, the most practical and cost-effective thing to do was to make a completely new shell and then graft it onto the fender.

Steps:
1. Cut the original car body tail light housing.

2. Make a pattern from the original and cut a new piece of sheet metal to match.

3. Shape the new part, using the old part and the actual taillight until it fits perfectly.

4. TIG weld the new sections together.

5. Put it on the car body, adjusting again until it fits perfectly. Cleco instead.

6. Check the bottom, top and sides against the measuring box for perfect squareness and symmetry.

7. TIG weld the new casing to the Ferrari body.

8. Finish the metal and then you’re ready to paint!

Visit my website to see step-by-step photos of the measuring box and this process.