Re: 57 Chevy Wagon - Californa Dreamin'
 

seats look awesome!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, John!
Thanks, Chip, new color on the firewall and interior of the black truck looked great when I was over with Boppa the other day. Like you, I'd appreciate some good painting weather instead of this single digit crapola.

The brown truck showed up today with new fenders for the wagon. I dug the originals out of storage a couple of weeks ago and decided the effort to repair them wouldn't be worth it. The areas around the headlight bezels needed a LOT of attention as well as places I'd previously patched. Summit had a great deal on the Danchuk fenders, so I popped for them and will swap meet the OEM stuff. Unfortunately, the new RH fender had a really ugly fold in it so it went back. Spent about a half hour on the phone with a nice lady at Summit CS. She handled the claim number the UPS driver gave me as well as placed the order for the replacement fender. Always something.

I got the rear inner wheelwells smoothed out and ready for upholstery - not that that will happen anytime soon. I also rigged up a hinged cover to allow access to the EFI pump in the fuel tank. Not gonna get hung out to dry like I did with my last project.

I contacted a company about doing spray chrome on the grille bar. I'm also waiting to hear from a local sign shop that does wraps to see if they think they can do chrome vinyl on it. I'm concerned that the fine detail around the emblem in the center may be beyond the limits of the material. That said, the guys that work with that stuff do some amazing things. We'll see what they have to say.

Monday is predicted to be a bit warmer so I'm hoping I can get Feather Fill on some of the pieces. I have about an hour of work left on the rear hatch and the body work should be complete... except for stuff I've probably overlooked.

Re: 57 Chevy Wagon - Californa Dreamin'
 

I tell ya man, you are on whole nuther' lever Vic. Every time I come and check in I'm amazed at the cleanliness of your work. Thanks for posting what it should look like!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Wow, it's been a while since I've been on here, but you've done quite a bit! Looks like nice work Vic. Keep it up!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Love seeing updates here. I'll have to Google spray chrome. I can't think a wrap would fly, but like you, I'm always amazed by that stuff!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Looking great Vic.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Brian. When you're old and retired you can dink around until you get it the way you want. ;)
Hey Duane, I need to make some progress if we're going to make the TriFive Nationals in August.
Thx, John. After talking with the guy that does the wraps, I decided to go with the spray chrome. He'd never actually done chrome vinyl and I was concerned some areas of the bar might present a steep learning curve. So the grille bar has been at the spray chrome place since last week. No word yet on when it will be done, but he sounded like he preferred to collect several pieces before firing up the equipment. Said it takes an hour to get the equipment to the right temperature to spray and then two hours to clean up, so it's more cost effective to do multiple jobs. Speaking of which, he said it costs him 48 cents per second when he pulls the trigger.
Thanks, Dale.

I was able to lay down some Feather Fill and 2K primer recently. Still a lot left to do, but now I can block a bunch of stuff when it's cold outside. I'm deep in the middle of that right now. I anticipate more nice days in March so it won't be long until it's all one color... gray!

Kathy and I went to the World of Wheels show last weekend and talked with one of the owners of Hot Rod Express in Blue Springs. Their shop is only 25 miles from the house. He seemed enthusiastic about doing the paint and was willing to take it over when I felt it was ready. We went to their shop on Tuesday and got the nickel tour. They provide a full range of services - fabrication, mechanical, paint and body, upholstery, transport and etc. We're tentatively setup to deliver the car to him by the end of March and they'll do the final blocking, paint and cut / buff. I think this will work out better than hauling it all the way up to Iowa, especially since the earliest they could get me in was late spring.

Fingers crossed this works out.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Good luck with it Vic...its looking good

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Greg. Hope to have it looking even better in the coming weeks.

Re: 57 Chevy Wagon - Californa Dreamin'
 

It's looking great Vic. I'm looking forward to seeing how the grill bar comes out. The spray chrome is interesting me.

Re: 57 Chevy Wagon - Californa Dreamin'
 

I've seen that spray chrome used on TV shows..never seen it in person...hope it turns out good...

Re: 57 Chevy Wagon - Californa Dreamin'
 

Me too, Dale. Still waiting to hear from the guy about his progress. He's had the bar two weeks tomorrow.
I've mainly seen it on YouTube videos, but not in person either, Greg. We'll see I reckon. ;)

I've completed blocking all the Feather Fill on the body and doors. Tomorrow if the weather cooperates, I plan to cover it all with several coats of 2K primer. My goal is to prep the firewall and door jambs, paint the dash and let HRE do the final blocking on the exterior. When they're happy with everything, they'll paint, then cut and buff.

Still a lot to do. I need to apply the 3M Body Schutz on the underside, set the body on the chassis and mock up the front clip to see how the reproduction fenders fit.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Looking GOOD Vic. Better weather will help!!!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Jay, we're due for a few warm days fer sure.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Had a few days just warm enough to be able to prime some parts. Due to being shortsighted, I ran out of material with a bit left to do. Ordered up some more which should be here on Wednesday according to the tracking. You can see from the first photo below what happens when a wobbly, weak old person tries to pretend he can still paint. Fortunately, it's just primer and it blocked right out but it illustrates why I'm delegating the actual paint job. ;)

Meanwhile, I've made the filler panels for both sides to cover the areas I cut out when installing the suicide hinges. Also needed a couple of plates to cover the spots where the original tailgate retractors fit. Now that the rear hatch is one piece, those are gone. I also spent a little time under the car tidying up the floor pan before it gets body schutz. There's also some places that will need seam sealer replaced from having the body dipped. Hope to get the floor pan coated from the firewall back to the rear wheel wells this week. So I'll be doing a supply run to the paint store tomorrow.

Being a tightwad, I'm blocking the jambs, the firewall and the dash to save a few bucks. I'd rather spend a bit extra on the outside where it matters. Lots to do and the Tri-Five Nationals will be here before you know it. We're hoping this coronavirus thing has faded away well before then. If it lurks around it could put a damper on all kinds of fun stuff.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Looks good Vic...I've had my share of those paints sags...hoping I can pull mine off without having any this time..

Re: 57 Chevy Wagon - Californa Dreamin'
 

Your car is going to be beautiful!

Re: 57 Chevy Wagon - Californa Dreamin'
 

�� it’s starting to get exciting knowing your going to have paint on it before long.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Greg. At least it was just primer and easily fixed. I'll be interested to see how your booth setup turns out... and good luck on the paint!
Thanks, Mike, I hope it turns out nice. Lots of hours in it for sure.
Hey Scott, I'm thinking it will be ready by the end of the month and with any luck, so will Hot Rod Express. We'll see.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Kathy and I had planned to drive to Houston this weekend. I was going to fly back on Tuesday and she would make the trek back on her own later in the week. We decided to err on the side of caution and stayed home instead. Will go down in the fall when things are (hopefully) back to normal.

So I forged ahead on the wagon. Everything from the firewall back is in primer and I've blocked the door/body jambs, the firewall and the dash. After hanging the doors and getting them more or less adjusted, I laid down some fine line tape to show where I plan to break the two tone. The bottom color will be Firethorn Red Pearl and will peek about an inch above the upper stainless trim on the quarter and rear door. It will disappear into the trim in the middle of the rear door and then split the trim all the way forward to the front. The upper color will be Millennium Silver and where the red and silver touch on the rear quarters and the jambs they will be separated by a bright orange pinstripe.

I've also started prepping the reproduction front fenders. As you can see from the photos, there are quite a few tooling marks around the headlight areas. There are other places as well, but they'll probably block out with several heavy coats of primer. Supposed to be cold and rain all week so once the EDP is scuffed, I'll have to set the hood and fenders aside and work on other things till I get a nice day. Will probably get the bulk of the underside in Body Schutz this week. More photos when I have some progress to report.

Re: 57 Chevy Wagon - Californa Dreamin'
 

You have been hard at it. It sure is looking good.

Re: 57 Chevy Wagon - Californa Dreamin'
 

It's looking better with every update. Keep it up!!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Jay!
Will do, Dale, thanks!

One of the members on the TriFive forum suggested that I pre assemble the air ducts, headlight buckets, headlight bezels and grille surround moldings before going too much further. Good idea as it turns out. Nothing wants to fit. Spent a lot of time with the hammer and dolly just to get the bezels halfway close. Most of the guys that eliminate the air ducts end up cutting the stock ones down, but the fit is so lousy on mine, I'm half inclined to fabricate the parts I need. Real Deal Steel sells them but you end up shelling out almost $150 for a pair. For just some scrap sheet metal and two days of cursing, I can have the exact same parts. ;)

Re: 57 Chevy Wagon - Californa Dreamin'
 

Gotta love aftermarket sheet metal. I bought new fenders for the C10 so I didn't have to fix the rust in the factory ones, but the aftermarket stuff fit like such garbage, it'd be less work to just fix the factory parts. I wound up using the aftermarket fenders for a desk in my office. :lol:

I'm sure I'd have spent as much time working on them as you have if my factory stuff weren't as nice (decent is probably more like it) as they are. I feel your pain though. Keep it up, you're doing great!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Duane! As you can see, I'm hard at work modifying OEM pieces to fit these fenders. Read on for more sheetmetal misery...

After making a couple of patterns, I decided to do what most of the Tri-Five guys have done and cut off the front section of the air duct. I tacked in a block off plate for the sake of appearance and to make it more rigid. Used brushable seam sealer to close up the gaps and painted it flat black. Had to grind off some of the lip on the fender and slot the mounting holes slightly to get the headlight bucket to fit. But it allowed me to test fit the headlight bezel and the grille surround trim. As they say down in Texas where we lived for many years, "Fit like a saddle on a sow." But they were close enough for starters.

Re: 57 Chevy Wagon - Californa Dreamin'
 

You can see from the photo with the yellow arrows that I had some gaps to fill around both the grille surround and the headlight bezel. I taped off the parts and applied filler completely around the bezel and all along the grille surround. After the filler set up a little bit, I removed the shiny stuff and waited for the filler to harden completely. I sanded the excess down to the parting line and then re-taped all the edges and added some filler along the lips for backup. A bit more sanding and I had a nice base for the bezel and surround to seat up against. So the passenger side is done except for several coats of high build primer and blocking.

The last photo is the driver side. It has a much bigger step than the one I just finished, so I'll have to blend the filler further back on the fender. Stay tuned.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Nice work Vic!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Scott. The driver side headlight bucket area is pretty much done. I'll need to assemble the full front clip on the chassis to know what else I may need to adjust but the gaps and steps between the fender and the bezel / grille surround are as good as they're gonna get for now. I still need to apply the body schutz on the underside and scuff the hood (top, edges and bottom). It looks like we may have good weather by mid week, so I'd like to be ready to shoot some primer, etc.

Re: 57 Chevy Wagon - Californa Dreamin'
 

You got that fitting good..!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Looking great, nice job on the fenders. You're definitely using a lot of patience. A lot more than I have....

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Greg!
Thanks, Dale, patience is about all we can exercise these days. The city has issued a stay at home order for the next 30 days, so working on a project car is about as good a time killer as I can think of. The hood is the last piece of the front clip needing prep. We're supposed to have a 70 degree day on Wednesday, so I'd like to get the rest of the parts in primer then if possible.

Today is the last day before the new rules go into effect, so Kathy and I made a quick trip to storage and emptied it out. Luckily, we had the place to ourselves. All my "stuff" is back under one roof but will need to be reorganized when I move the chassis from the upstairs garage into the basement workshop. Right now, it's all underfoot but that will just be temporary.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Yer a frekkin magician!

Re: 57 Chevy Wagon - Californa Dreamin'
 

:lol: Thanks, Mike, although persistent old fart is perhaps a better description. Today was warm enough to lay down some primer. I was forced to stay just inside the garage door, though, because the wind was pretty gusty. I'm almost ready to transfer the chassis downstairs as I'm about out of stuff to primer.

I scored a Leed rotary vane vacuum pump off eBay the other day. Seller said it had been installed but never actually used. It had a little cosmetic damage to the canister, but I fixed that and will paint it silver to match the car. It's a hefty little booger. It may take some finesse to stash it in an out of the way place. I'm thinking under the driver side front fender. From what I understand, you can mount them almost anywhere with no loss of performance. It came with 6' of hose, so we'll see what works out.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Rolling chassis is back downstairs in the workshop. The next few days will be exhausting. ;)

Re: 57 Chevy Wagon - Californa Dreamin'
 

Very Nice!

Re: 57 Chevy Wagon - Californa Dreamin'
 

very nice Vic..!!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Thanks, Regan. Super Street truck looks cool ...and hauls! Do they still have a strip in Tyler?
Thanks, Greg, fixing to see if I can assemble the Flowmaster universal stainless exhaust. Right now it looks like a pile of Legos for big boys.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Looks like fun Vic. As far as a Drag Strip around here? Our track Interstate 20 Dragway has been gone since the late 80's.

Re: 57 Chevy Wagon - Californa Dreamin'
 

Nice exhaust kit! I'm sure you'll make it look great!

Re: 57 Chevy Wagon - Californa Dreamin'
 

Years ago when we lived in Houston and ran a S/G car, we made plans to race at Tyler (I-20) but seemed like every time we did, it rained out. So I never got the chance to make a pass there. Went to a lot of tracks back then, some of which are no longer in operation... Porter, TX, the old Houston International down by LaMarque, Green Valley up by Fort Worth just to name a few. Made my last pass in 1984 if that tells you anything. ;)
Thanks, Scott. I've gotten a bit sidetracked with small projects and have yet to start laying out the exhaust. Both the oil and trans dipsticks needed to be shortened, which is easier said than done. I guess the folks that designed the ones I have wanted you to be able to check the fluid levels without having to lean over the fender. The oil dipstick is now underneath the header tubes and requires that I pull the spark plug boot above it for access. The trans dipstick now sits just behind the cylinder head instead of snaking way over the top of the injector rail. Both are hardened steel which meant I had to drill the holes for the retaining pins with a carbide drill. But, it's finally done.

The dust shield for the flexplate is another issue I'm dealing with. The one they sent me is for a manual trans setup and won't clear the Mast Motorsports pan. Plus the holes meant for bolting it to the bell housing are not at all like what I have. I think the 4L70E trans that came from Performance Automatics is a hodgepodge of parts. The bell housing is most likely from a 5.3L Vortec truck. In fact, I had to machine a press-in mounting boss for the trans dipstick because there's no corresponding threaded hole in the 6.2L block.

You can see the difference between the dust shield I received and the pattern I made that follows the actual contours of the bell housing and oil pan. Moroso makes one a bit more generic than mine, so obviously others have had this problem. I made a quick trip to the metal store this afternoon to pick up some .090 aluminum sheet to use with my pattern. Had to call in the order and when I arrived, there were no vehicles in the parking lot. They had a phone number posted by the door where you pick up. Called it and they came out and loaded my stuff into the back without me having to get out. Weird ...but necessary I reckon. So tomorrow I can whittle out the dust cover and then there's no other excuse I can use for delaying the exhaust fabrication.