George Barris built this 1941 Ford convertible based custom for John Vara. The completely finished car was traded to Johnny Zaro soon after completion. The trade was for Johnny’s Barris built 1940 Mercury coupe and some extra money. The 41 had much more extensive body work and would have cost quite a bit more money to create. In this article there is one photo showing both customs side by side. Probably taken the day the trade was made. Incidentally both Zaro customs still exists today and are completely restored.
The convertible body was channeled over the frame 8 inches. The frame itself was kicked up another 3 inches in the back. This combination resulted in an ultra low ride with still maximum comfort.
After the body was channeled over the frame the front fenders where raised about the same amount to make sure the front wheels could still turn . The hood sides where cut to clear the raised front fenders and the edges where flared into the new fender line. The front of the hood was cut off and welded to the front of the fenders. The whole front of the car was welded into a one piece unit, the headlights where molded in and a new opening was created to fit heavily modified 1948 Pontiac grille bars. A 1946 Ford front splash pan was molded to the fenders and a 1946 Ford bumper was installed. Both where installed rather high compared to the side of the car. Most likely this was done to make the car appear not to be as low as it really was. The new fender line sits now almost level with the top of the hood when viewed from the side.
The new raised front fenders where extended rearwards using shaped sheet metal. A wonderful flowing line was created from the top of the front fender on slight angle towards the rear fender. The rear fenders where molded to the body with a smooth radius to the body. The same radius was also used to mold the fade away fenders into the side of the body. The main body was also sectioned, but unsure is where this was done if it was done at the middle of the body or “simply” by cutting material from the bottom of the body. Known fact is the total height of the car was just 56 inches.
The new door lines where modified and now open up all the way to the bottom of the body. (Suggesting the body sectioning was in fact done by removing material from the bottom of the body). A lot of careful construction work was needed at the front of the doors to make the hinge mechanism work with the fade away fenders. The windshield was chopped several inches (4.5 inches according the July 1951 Motor Trend feature, but I think it was less than that). Twin Appleton s-112 spotlights where installed at the base of the windshield pillar. 46-48 Ford accessory fender skirts where installed and a 1946 Ford rear splash pan was molded to the body. A 1946 Ford bumper was also used at the rear. At first the stock bumper guards had small round motorcycle accessory taillights attached to them but soon those where replaced with home made inserts into the bumper guards. Together with Jesse Lopez 41 Ford the Zaro 41 Ford was among the first to use these bumper guard taillights. The smooth trunk was reworked to accept a inset license plate. Cut with nice radiused corners and fitted behind a piece of glass or plex the license plate now become part of the car rather than sticking on a bumper. Strange thing is that the front corners of the trunk where not rounded, which creates a rather sharp line compared to the otherwise smooth and rounded body.
The chopped padded top was created by Louis Chavez from Lynwood. The wide tuck & roll interior was stiched by Bill Hilborn out of Inglewood. Exceptional for this custom interior was the rear seat which incorporated a small bar. Something not really common for custom car in those days. The dashboard was smoothed and chromed with accents of hand crafted clear red plastic trim pieces.
When Barris had just finished the custom a set of smoothed hubcaps was used. But when Johnny Zaro owned the car those where replaced with all time favorite Cadillac Sombrero hubcaps. The car was painted an ultra deep and dark metallic maroon.
After driving the car like this for some time Johnny brought it back to Barris for a mild update on the grille. Barris used a 1949 Pontiac grille bar with the vertical teeth removed and remaining holes filled Below the vertical bar Studebaker teeth where used. At this time the car was repainted Tokay beige. But soon Johnny had Barris repaint it again in a deep maroon paint. This time Polychromatic maroon with a lot of gold powder and many clear coats for ultra luster. The dark color suited the custom much better, giving it more elegance that the beige could ever do.
