Restoring a classic car can be fun, but it’s not inexpensive, especially if your project car is rusty, dented, or rotted. Quality shops charge over $200 per hour for major body work, so costs can ramp up quickly. Fortunately, companies like Real Deal Steel and Dynacorn - opens in new window or tab. offer complete, brand-new body shells for many classic cars, making your restoration project look brand-new without expensive, time-consuming repairs.
Restoration parts companies have long offered new steel replacements, like front floor pans - opens in new window or tab. or door skins - opens in new window or tab.. Eventually, these companies realized there was a market for complete reproduction body shells. They licensed the body designs from the original automakers and contracted steel stamping companies equipped for large dies and molds.
From Firewall to Tail
Most classic car replacement body shells are produced overseas. Individual body panels are manufactured to the exact original dimensions, then placed in jigs and meticulously welded in place. The bodies are sold unpainted, but most companies coat the steel in electro-deposit primer to prevent corrosion during shipping.
The typical replacement body shell goes from the firewall to the taillight panel. (The front bodywork is a separate assembly attached to the frame on most classic American cars.) Bolting the new body to the chassis is just the beginning. Joe Whitaker, co-owner of Real Deal Steel - opens in new window or tab., says that a customer should plan on 60 to 80 hours of fitting and bodywork to achieve a high-quality outcome. Then comes the lengthy process of assembling the windows, door handles - opens in new window or tab., weather stripping - opens in new window or tab., interior door panels - opens in new window or tab., and exterior trim moldings - opens in new window or tab. that turn a new body shell into a complete car.
Smart and Easy
Given the rising cost of decent donor cars, a new reproduction body shell can be a financially wise option. eBay offers new body shells for all sorts of makes and models, but be prepared: Most vendors have a waitlist, and delivery can take up to nine months.
As reproduction body shells become more popular, manufacturers are adding new models to the mix. Tri-Five Chevys - opens in new window or tab. and first-generation Ford Mustangs - opens in new window or tab. were some of the earliest offerings, but Camaros - opens in new window or tab. and Chargers - opens in new window or tab. soon followed. With classic American cars, many body pieces are interchangeable from year to year. This makes it easier for manufacturers to offer a variety of replacement shells. But it's not just domestic vehicles. The 1960 Volkswagen Bus - opens in new window or tab. reproduction shell offered by DAC Motorsports - opens in new window or tab. is a lifeline for folks restoring hopelessly rusted Sambas. DAC offers 1968 Ford Mustang fastback and 1969 Bronco shells, as well.
Better Than the Original?
Many manufacturers say modern steel is superior to what automakers used half a century ago. Reproduction body shells often have thicker, stronger sheet metal. New body shells are assembled individually, focusing on high-quality fit and finish. Whitaker says that while most parts are stamped in Taiwan, they are assembled into complete shells in the United States to save on freight costs.
If you’re about to dive into a complex classic car restoration, check out eBay to see if a replacement body shell makes sense. Brand-new bodywork isn’t cheap, but it can often save you time, money, and frustration getting your project car back on the road and looking great.
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This article is meant to provide general guidance only. Automotive maintenance, repair, upgrade, and installation may depend on vehicle-specifics such as make and model. Always consult your owner's manual, repair guide for specific information for your particular vehicle and consider a licensed auto-care professional's help as well, particularly for advance repairs.