After hundreds of hours spent saving an abandoned 1980s Nova, the team behind Hudson Auto Films thought a replacement roof canopy might make the job easier. Instead, the better-looking part turned out to be the wrong shape.
The unusual kit car had sat in undergrowth for decades before the YouTube creator bought it. He has since worked to rebuild the Nova, including plans for a turbocharged Alfa Romeo race engine.
In his latest YouTube video, Hudson shows the work that kept the project out of sight for weeks. Beneath the old finish, the fiberglass body was full of cracks, holes, and rough repairs. Even its once-sharp lines had been sanded down over the years.
The footage covers about 10 weeks of work, but much of it is hard to see. By the end, Hudson also explains why the car has been taking such a toll on him.
The Damage Runs Deep
Fiberglass does not rust like steel, but it can still wear down. On the Nova, the shell had soaked up years of neglect. Past repairs had left bumps and low spots that would stand out under glossy paint.
The crew packed fiberglass filler into cracks and holes, then sanded it flat. To check the shape, they used a long sanding block across the panels. Dark patches showed where the surface stood too high, while low spots needed more work.
One round of repairs went wrong when filler on the front end would not set. Hudson thought the hardener might have been old. Whatever the cause, he had to scrape off the soft mix and start again. It was a painful setback after weeks of the same work.
A Roof That Won’t Fit
Hudson hoped a canopy from a donor Nova would save time. It was in better shape than the original, so he lifted off the old one and tried the spare.
The front looked promising. Then he checked the sides. The donor canopy was about an inch too narrow on each side, while the rear gap was wide enough for his hand. Moving it to fix one edge only made the others worse.
After Jamie came by to help, the two put the old gray canopy back on. It still needed major repairs, but at least it was closer to the right size.
The donor rear bumper brought better news. It was bent and full of holes, yet its thin fiberglass let Hudson pull it into place. Once bolted down, the bumper lined up much better with the body.
The Work Takes Its Toll
With most panels in place, the team filled old holes for the fuel filler and coolant tank. They also built up worn edges, sanding them into sharper lines. Some areas were finally taking shape, though Hudson said the body needed about 25 more hours before its final primer.
He also spoke about why the Nova had been missing from the channel. The project helped him make YouTube his full-time job, but the pressure to get it right had become hard to manage.
“I think I just burnt out,” he said. Parts delays had slowed the engine work, and he had held off on wiring to keep it clear of sanding dust.
Hudson now plans to move ahead with other parts of the build, even if the body takes longer. He wants the Nova ready to drive by summer 2027, a deadline he set while admitting there is still a great deal left to do.