In, Out and Under – Part 5 of the Goodguys 2025 Giveaway Monte Carlo SS Aerocoupe
There’s an old saying that when you only have a hammer, every problem looks like a nail. That may be true, but when you have a shop full of fabrication equipment, every obstacle on a custom build project appears like an opportunity to craft a creative solution. That certainly seems to be the case at Goolsby Customs, which is one reason Goodguys appreciates having the shop building their 2025 Giveaway Monte Carlo Aerocoupe.
As we detailed in the previous build installment, the Goolsby crew put its fabrication skills to work widening the car’s original rear wheel tubs to accommodate the wide wheels and tires combined with the low stance delivered by the Roadster Shop chassis. Shop owner Jonathan Goolsby had pondered what might need to happen to achieve similar wheel and tire clearance in front, where the original inner fenders are plastic and difficult to modify. The solution ultimately ended up being what the shop does best: fabricate new steel inner fenders from scratch.
As can see, the Goolsby’s team made this process look easy. They started by making a paper template of the primary inner fender piece, which was transferred to steel and given its initial shape in a slip roll roller. From there, it was a matter of refining the shape, rounding the edge to meet the vertical inner piece, and then fabricating and welding on that vertical piece. The resulting inner fenders are not only wider, but also smoother than the stock plastic pieces, which will give the engine compartment a cleaner look.
This fabrication work was being completed while bodywork was being done on the exterior sheet metal. As we had shown in Part 3, the body was coated in gray epoxy primer after being media blasted. A skim coat of filler followed, which was then block sanded to begin achieving a smooth, flat surface. This also resulted in breaking through to bare metal in a few areas. That bare metal was touched up with black epoxy primer, and then the entire body was masked off again, rolled into the spray booth, and coated in BASF polyester primer. This high-build white primer will provide a foundation for the next round of block sanding to create an even flatter, smoother surface for paint.
With the completion deadline looming, multi-tasking on the Monte has become mandatory. Fortunately, Goolsby recently hired a fabricator who also has interior and upholstery experience, allowing him to bring that aspect of the project in-house. So, while fabrication and bodywork were being done in one portion of the shop, in another area Jeremy was busy stripping the seats down to bare frames and mocking up new door panels. New upper door panels were fabricated from scratch, while the lower panels are molded plastic reproduction pieces from Dixie Restoration Depot that incorporate pods for 6-inch door speakers. The crew at Dixie was kind enough to supply many interior and trim parts for the project that you’ll see in upcoming installments.
As you’ll see, progress on the 2025 Giveaway Monte Carlo SS Aerocoupe is advancing quickly, though there’s still much work to do. You can rest assured the Goolsby crew will get it handled, though, and that the finished car will sit right, look sharp, and perform exceptionally well. We can’t wait to see it come together – and see it in person at the upcoming Goodguys 26th Summit Racing Nationals presented by PPG in Columbus Ohio, July 12-14.
Check out the other Build Stories about the 2025 Giveaway Monte Carlo SS Aerocoupe: Part 4, Part 3, Part 2, Part 1
Photos by Goolsby Customs
