Q:   Why does everything have such tight deadlines? You mention the Corvette had eight weeks to be built. Doesn't quality and employee morale suffer badly? Also, do you think Boyd is being portrayed fairly? Is the show turning out like you planned?
A:   The deadlines are pretty insane considering the total amount of work that goes into some of these builds. To answer some questions maybe this will help:

1) Yes, the deadlines are real! I shared in the insane amount of time spent to complete the upcoming Corvette by putting in 200+ hours of overtime. This was by far the most difficult build to date; it required seven-day workweeks and 12- to 14-hour days. Deadlines usually revolve around a particular event, which wraps up the build and the vehicle is debuted.

2) Boyd's can be a complicated place to work. With SOOOO many projects, including both customer cars and special American Hot Rod builds, life at the shop gets stressful. Sometimes (most of the time), it is a three-ring circus of confusion as to how to get everything finished. Duane does the best he can to keep everybody and everything moving in a forward direction, but trying to keep both the customers and Boyd happy can be "mission impossible." Tensions run high at times and that's when it can get tricky to stay on top of things.

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Q:   In the Bud Light build, there was a day when Roy wasn't in and you guys made some changes that he wouldn't approve of. This got me wondering how you guys decide to do a build. Do you discuss it before you start? Is there one person to make the decisions, or do you dive in and decide as you go along?
A:   When changes are made during a build, sometimes, not everybody (i.e., Boyd) agrees with what is proposed. For myself, I don't suggest something unless I have gone over in my head and on paper as to how it will affect the 20 other pieces it directly relates with. It's always a good idea to get other input for what you want to do because someone might have a different perspective and a better idea for the solution.

Planning is usually a rushed affair at the shop due to the tight deadlines, but I'm always pushing to do as much as possible because it really does lead to a better product and a happier customer.

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Q:   I see a lot of the guys TIG welding the parts to the cars. Are the guys certified welders? And do they ever X-ray the welds for penetration?
A:   Yes, we do use the TIG welders all the time. MIG works great for quick tacks when you're working on a piece by yourself, but usually things get finish welded with a TIG. As far as certifications go, we all have been to "school" for welding but not everybody holds a certificate. While our cars don't have to go into space, they have an even tougher inspection (Boyd and Duane) for weld quality before anything gets painted, plated or coated.

Another area is aluminum, which is my second favorite to weld, second to stainless. I just really like the look of perfect little "dimes" layered on top of each other.

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Q:   I would love to get good at aluminum welding. I've only tried it once though. Any quick advice for a beginner?
A:   The only advice I could offer for learning to weld aluminum is the same that goes for all metals: practice, practice, practice ... The more experience you can get, the better. Getting the "feel" for the metal and knowing how to read its surface is the most important first step. Aluminum can be more difficult than steels simply because you have a shorter threshold from solid to molten. After knowing what to look for, then comes the time in the saddle to work on torch/pedal/rod control, a delicate coordination that usually takes some getting used to. Keep on welding.

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