custom 1948 Lights Behind Grill on S3

[LH Drive]

Since i'm getting rid of all the plastic bits on my Series 3 and converting my bulkhead to an S2, i'm also gonna make a huge change on the front end. I've always liked the look of the first year Land Rover so i've been thinking of a way ti incorporate it into my series 3. Would like it to resemble the lights behing the grill look.
Was thinking of cutting up my S3 radiator panel since it aprears to look close enough and add lights. After a few weeks making cardboard templates, I figured it was going to require alot of cutting and adding more material that I decided to build from scratch instead. It will be constructed out of aluminum to compliment the brimabright body panels. The first step I took was to make a wooden template that gave me a more 3D item to work with. The original 1948 grill is different size/shape than my S3 panel so I had to move some measurements around. This is what I came up with and used a jig saw to cut the wooden template.
I already had some new aluminum wire mesh and jus tneed to get some aluminum rod and bend up the outer shape to wrap the mesh. This part will not be difficult.

I'm still not sure just how to construct the new radiator panel as i'm not a metal fabricator. I don't want to farm out the work as I want it to be something I did with my own hands. I plan to hand work a thin aluminum sheet with hammer/dolly, measure and cut the inside panels where the lights and radiator will mount. Then have a metal shop weld it together like when I buld my swing out tailgate.
Just need to find some workable gauge aluminum sheet that will have enough strenght but be easy enough to hammer/anneal.
Has anyone worked with aluminum before?

[LH Drive]

The wooden template was nice as it shows me how it will look mounted. My first wooden template had to be scraped, after it was installed, it just didn't look right.
This is the second template I made and the one I'll be using to make my grill. It had to be taller than the original S3 radiator panel in order to have the raised hood like on the original 80" Series 1.

[LH Drive]

I'm satisfied with the way the raised hood is going to look. The front metal frame section will need to be reworked to fit the new arched radiator panel. A new aluminum skin will be fitted to the hood frame to fill in the large gap I created. I will not be using the S3 hood catch, its gonna have the older style outer hood latch like the Series ones came with.

[jac04]

Interesting idea. For the radiator panel, I think you will need a significant inner structure (either aluminum or steel) for strength to support the radiator, hood, spare tire, wings, etc. It will also need to be able to take repeated opening/closing of the hood. A welded steel inner structure may be the way to go. You could even make it all out of steel and have it galvanized to compliment the bare aluminum body panels.

[LH Drive]

jac04, your right about making a significant inner structure to support all the weight. I'll see what I can find to make a good structure. I might have some left over 3/8" thick 1"x2" boxed aluminum left over from my tailgate project. Gonna try and build it out of aluminum but if the estimated cost is to high then steel will have to do. When its done it will be painted bronze green anyway.

[SafeAirOne]

Interesting project. I kinda like the lights-behind-the-grille look.

Just curious about raising the front of the hood a few inches...What's the puropse? It looks like the hood will end up having a reverse slope, where it's high in the front and angles down toward the bulkhead unless you're planning to raise the hinges on the bulkhead also.

...plus, it seems like a lot of work compared to a simple reshape of the upper surface of the panel you're building.

[LH Drive]

Interesting project. I kinda like the lights-behind-the-grille look.

Just curious about raising the front of the hood a few inches...What's the puropse? It looks like the hood will end up having a reverse slope, where it's high in the front and angles down toward the bulkhead unless you're planning to raise the hinges on the bulkhead also.

...plus, it seems like a lot of work compared to a simple reshape of the upper surface of the panel you're building.

I thought the same but after looking at other pictures I found that the older Series 1 hoods were almost level to the ground. They look to be the same height in front as bulkhead mount. On Series 3 they tappered towards the front and are 1 1/2 inch lower than at bulkhead. That's all I raised it and looks to be much higher in the front but my hood is now level with the wings.
I found a picture that shows a series one next to a series 3 hood. The series 1 hood is also shorter and the reason i'm having to reshape mine.
The whole purpose is to give it the 80" front end look. One of my first templates was to make it the same height as the original S3 radiator panel. It just did not look the part. I'm even goint to chop about 2 inches from the bottom of the front wings near the bumper. The 80" seams to have this done as well as squared off rear quarter panels.

[yorker]

Are you going to remove the side marker lights from the front wings too?

[LH Drive]

Are you going to remove the side marker lights from the front wings too?

yorker, Due to my Series being a 1972 it will need to have the side markers. I might also need to have turn signals on the front wings. I'll look into that when the build is near complete. In our state they offer a Hobby auto registration plate for custom builds and replica autos. My drivetrain will be 100% series 3.

[ArlowCT]

Are you planning on keeping the lights out on the wings too? Moving your only source of light to behind the grill will cause a bad case of tunnel vision i would think.

If I remember correctly the ser I has shorter fenders too. I'm thinking they do not stick out as far past the breakfast as the ser II-III do. I have always liked the looks of the ser I the best. Great project, good luck.

[SafeAirOne]

yorker, Due to my Series being a 1972 it will need to have the side markers.

With that arguement, being a 1972 it will also have to have the lights out on the wings. They were moved to the wings to comply with the motor vehicle regulations of foreigh markets (probably USA, amongst others)...

[LH Drive]

Made some progress on the aluminum grill today. The first wooden template I messed up on was usefull as it served as the pattern for the grill. After figuring out just what would be a good size for the new grill I transferred the measurements to the wood template and cut to size. Secured it to a sheet of plywood that served as a work bench and started forming the 3/8" aluminum grill frame. Once the frame was formed I secured the aluminum wire mesh in place so it wouldn't move as I wrapped the ends of the mesh to the frame.
It already looks good, can't wait to see it done.

[o2batsea]

There is something called annealing, where you heat the metal up to a point below melting and allow it to cool slowly. This removes the temper making it soft like butter. You can shape it while in this state, as long as you don't work it too much as it will work-harden to some extent. When you are done working the metal you heat it again but this time quench it quickly in water which restores the temper.
I don't think these mods will make any difference to any authorities unless you either try to sell it or attempt to pass it off as being original to the vehicle when having it inspected as a regular vehicle. If you get it registered as historic or as a street rod you can get away with anything. Simply keep the old parts so that it can be easily returned to its OE spec.

Not my cup of tea, but certainly easily fabricated.

[LH Drive]

o2batsea, thanks on the annealing hardening tip.

Finished the aluminum mesh grill today. I also painted the wooden panel so it would stand out a bit more compared to white. I have enough material to make another mesh grill for an extra spare part and will be hung as garage wall art.

[LH Drive]

Trying to end up with something similar to this photoshopped picture of an 88" series 2 with series 1 front end. I like the turn signals out on the wings vrs. not having any. If I can't find the S1 windscreen hood brackets i'll have to bend some up.