1. This project started with a very sound and straight 1981 Z28 Camaro. Since the body required very few modifications, most of the effort was concentrated on the chassis, drivetrain, and the beautifully sculpted engine compartment.

Sheet Metal Symphony

BY RON COVELL

he treatment of the engine compartment offers a perfect opportunity to showcase both craftsmanship and design, all in service of highlighting the engine—the beating heart of any serious project vehicle.

BBT Fabrications is well known for its superb metalworking skills, and this 1981 Z28 Camaro provided the perfect canvas for the crew to create a custom-fabricated engine bay. Starting with an exceptionally clean and solid car that required very little bodywork or repair, they fitted a Roadster Shop SPEC Series chassis and installed a 376ci LSA engine with a Harrop supercharger.

Retaining the factory underhood sheet metal simply wasn’t an option for a build of this caliber. The BBT team began by reworking and smoothing the firewall, then turned its attention to creating a series of elegantly sculpted panels to enclose the inner fender areas and cover the radiator support.

At first glance, the finished design appears deceptively simple, but as with so many high-end fabrication projects, the real artistry lies in the details. In the following photos, we’ll take a close look beneath the surface to reveal the craftsmanship and problem-solving that went into every panel and contour.

The inner fender panels were fabricated first, beginning with an upper section that followed the inner flanges of the fenders while gracefully spanning the distance between the firewall and radiator support. These panels had to be carefully notched to clear the Eddie Motorsports hood hinges. Once the upper section was shaped and fitted, a second panel was formed to fit directly below it. After extensive tweaking and refinement, the two sections were welded together and metal finished into a seamless unit.

The lower panel was then fabricated to extend downward to the framerail. This section required additional notches to clear the front suspension components, and once properly fitted, it was joined to the upper panels to create a rigid, unified structure. Every edge was flanged to add strength, maintain flatness, and provide secure mounting points, while also allowing most of the fasteners to remain hidden from view.

Arguably the most complex component to fabricate was the radiator cover, which required numerous transitions in both angle and contour. Piece by piece, the crew shaped and refined the assembly until it blended perfectly with the surrounding panels, creating a smooth and cohesive appearance throughout the engine compartment.

The accompanying photos clearly document each stage of the fabrication process, and we hope this exceptional design and craftsmanship provides inspiration for your own projects.

2. After fitting a Roadster Shop SPEC Series chassis and a modern GM powerplant, the engine compartment was prepped for the extensive fabrication work to come.

4. The entire center section was cut away and replaced with a flat sheet metal panel. A brace of square tubing was used to keep the panel perfectly flat during installation.

6. After careful fitting, the panel is temporarily secured with magnets in preparation for tack welding.

8. The inner fender panels were fabricated from multiple sections. Here, the upper panels are being fitted where they meet the inner edges of the fenders, with relief notches to clear the hood hinges.

10. After extensive shaping and fitting, the first two sections were welded together and metal finished into a seamless assembly.

12. The panels are being fitted tightly against the firewall, held in place with Clecos for the final trimming before welding.

14. The driver-side panel was notched to clear the brake booster and master cylinder assembly.

16. All panel edges were flanged to provide rigidity, maintain flatness, and create sturdy mounting surfaces.

18. A subtle stepped detail was formed into the top of the radiator cover to add strength and visual interest.

20. Every joint was carefully massaged and metal finished for a smooth, uninterrupted appearance.

22. Fine-tuning was required to make the radiator cover align perfectly with the shape of the inner fender panels.

24. From the back side, the impeccable fit and craftsmanship of the panels becomes even more apparent.

26. The custom-machined radiator cap fits in the recess perfectly.

28. From the rear, you can see just how precisely all the panels fit together.

30. Both cooling fans are mounted here, highlighting the tight clearances and exceptionally clean installation.

32. Despite the extremely tight clearances, the inlet tube fits perfectly within the surrounding panels.

33. A filler section was added around the hood latch area to complete the panel transitions.