1957 Chevy truck re-rebuild
 

Hi everyone. My name is Jim, I've wondered the posts for a while now. There's nothing like pictures of other projects to spark others imagination, or just to get you through some tough spots by seeing what others have gotten through.

The short history... My dad bought and went though this truck back in the early 80's. He had help, but I don't think anyone really had their heart into the project. Before he bought it, it did have a front subframe from an el-camino installed. This was a great start to getting this truck on the right track.

He had it for nearly 30 years and maybe put a couple hundred miles on it. He never had the confidence to drive it too far. For instance, the 327 had some worrying sounds, the charging system didn't work well, the carb had a bad hesitation, ect.

As a gift for all he had taught and instilled in me over the years I finally got a nice workshop put together so we brought it over for a total redo. The plan wasn't to go too far from original, just get it to a turn key reliable truck. He was retired and I really wanted him to be able to drive it to car shows and enjoy the day anytime he wanted take a drive.

Sad to say, he passed away 4 months into the project. That was Sept. 2010. It sat in my shop til a couple months ago and it's time to finish it as a memorial project.

It took a while for me to get my heart into the project, first, it wasn't my truck, and it wasn't supposed to happen this way. Once I got back into the project, I recalled all the things he wanted to change and upgrade, once I got going I would imagine the excitement on his face as I got working on it again and my heart warmed to the project.

Ok, let me grab a kleenex here.... ;)

Onto the present time.

I'll run a few pics of where I am now and go back in time on how I got to where I am. I have details pics of most of the progress, if anything perks interest, let me know, I probably have good learning pics.

Most of the work is not nearly as deep as some of the projects I've been viewing, such as Kims truck, wow.

One area I just finished is the rear tailgate and bumper. Dad wanted the chains gone and the taillights mounted somewhere other than on the old brackets.
http://i1139.photobucket.com/albums/...k/102_2686.jpg

More pics to follow.

Re: 1957 Chevy truck re-rebuild
 

Hi Jim, looks good so far.

Re: 1957 Chevy truck re-rebuild
 

Welcome.
Do keep the pics coming.
Kim

Re: 1957 Chevy truck re-rebuild
 

More pictures I can do.....

One way they got rid of the taillight brackets back in the 80's was to install a different bumper. I removed the bumper before I got a picture of it, but it had the taillights built into the bumper. Taillight bracket issue solved..

My issue was the bumper was off a more square bodied vehicle. In other words, the front bumper on the truck was rounded, as it was original, and the rear didn't match the same flow as the front.

I ordered an original bumper and brackets. Now to satisfy the "no bracket" taillight situation.

By using the down post of the rear of the bed and using led reproduction taillights, I cut a half moon shape out of it. Then I fabricated an outer taillight housing to enclose the rest of the taillight.

The picture will explain better than I can.
http://i1139.photobucket.com/albums/...k/102_2710.jpg

Once I finished with the taillights I just felt something was missing. I walked by it for another week or so, then it hit me. Oh yeah, I remember something that was done back in the day.

I don't know what to call them, but both taillights got one.:)
http://i1139.photobucket.com/albums/...k/102_2725.jpg

Re: 1957 Chevy truck re-rebuild
 

Looks nice. I think they call them eye brows but I could be wrong.
Kim

Re: 1957 Chevy truck re-rebuild
 

you teasing us?
3 pics
all of the tailgate???
wtf? :D:D:D

Re: 1957 Chevy truck re-rebuild
 

Lol, would you get to the point.:lol:

Ok. will do.

I'll do a run of pics dealing with making the taillight out housings.
First mark where I decided to have the tailligts.
http://i1139.photobucket.com/albums/...k/102_2504.jpg

Once the half hole was cut I taped the light in place and used construction paper to get an idea of the size and dimention of the outer housing I had to make.
http://i1139.photobucket.com/albums/...k/102_2511.jpg

Once I had the construction paper cut for the front, back and outer pieces I used a Torchmate plasma cutter to convert the paper to metal pieces. The round item in this picture was made from 3" exhaust pipe. I will not be using the original housing, this round piece will be what will hold the led light and what the 2 screws that holds the stainless bezel in place.
http://i1139.photobucket.com/albums/...k/102_2537.jpg

Three inch pipe was too small, my only other choice was 4" that was too big. I used the 3" and split and spread it to the right size. Then welded a piece to fill the gap. At the time I had no 4" in my shop, otherwise I probably would have used it.
http://i1139.photobucket.com/albums/...k/102_2532.jpg

After a little grinding.
http://i1139.photobucket.com/albums/...k/102_2534.jpg

Both are made and the bezel fits great. I still have to weld the nuts inside the round pieces for the bexel screws to attach to.
http://i1139.photobucket.com/albums/...k/102_2533.jpg

Pieces tack welded together.
http://i1139.photobucket.com/albums/...k/102_2539.jpg

I cut with extra material so I could final fit the housings. Here is the test fit.
http://i1139.photobucket.com/albums/...k/102_2546.jpg

Once I got the pieces fitted, it was time for welding.
http://i1139.photobucket.com/albums/...k/102_2562.jpg

Although welded on the outside, the penetration was spot on.
http://i1139.photobucket.com/albums/...k/102_2559.jpg

The nice part of the torchmate is the consistancy of reproducing multiple items.
http://i1139.photobucket.com/albums/...k/102_2575.jpg

With the housings made I used them as a templet for the cut.
http://i1139.photobucket.com/albums/...k/102_2568.jpg

I welded the ring to the body first. There is a sheet metal ridge near the tailgate that got in the way of the welder tip if I welded it later.
http://i1139.photobucket.com/albums/...k/102_2605.jpg

After welding and grinding.
http://i1139.photobucket.com/albums/...k/102_2620.jpg

I hope that fills the picture needs for a while. ;) Enjoy.

Re: 1957 Chevy truck re-rebuild
 

Nice design and great fab work on the tail lights. Lookin' good.

Re: 1957 Chevy truck re-rebuild
 

Real nice work on the tail lights.
Kim

Re: 1957 Chevy truck re-rebuild
 

Goes perfectly! Knocked that one outta the park, well done!

Re: 1957 Chevy truck re-rebuild
 

You do nice work. That's why I like this forum, lots of skills and ingenuity on display.

Re: 1957 Chevy truck re-rebuild
 

Nice like the tail lights looks like a good start/

Re: 1957 Chevy truck re-rebuild
 

look good and the eyebrows are a nice touch!

Re: 1957 Chevy truck re-rebuild
 

ogre's are known for being subtle :D
nice tail lite mod
but we've still only seen the butt of your truck

Re: 1957 Chevy truck re-rebuild
 

I know everybody says this....but, thanks for the encouraging replies.

Most of you also have build threads and know rebuilding these old vehicles can wear on one's patience over time. Having a community with the same interests sure helps keep the momentum moving forward.

I have many different projects going on, most do not involve whole truck pictures. I'll move to changing the rear springs to the one's that lower the rear end, they have a couple whole truck pictures.;)

With the front change to independant suspension back in the 80's, the front dropped a couple inches. From what I can tell, they removed a couple leafs out of the rear to lower it to match the front. It did drop the rear but not enough for my liking.

I ordered the ones advertised as a 3" drop. Don't be fooled, I looked at the picture in the catalog for a long time, I couldn't see how it was gonna happen. Plus I didn't want a full 3" drop anyway, so I figured I'd be happy with a less than3" drop.

The design is great, they simple rolled the spring bushing eye the opposite direction on the rear or the leaf spring. This altered the rear of the spring a couple inches.

The front of the spring stayed the same however. Since the axle is located in the middle of the bushing eyes, the the drop is only a little over an inch. The front is still at the same pivot point.
http://i1139.photobucket.com/albums/...k/102_2401.jpg

This pic is with the old springs, even with the couple of leafs missing.
http://i1139.photobucket.com/albums/...k/102_2366.jpg

This next pic is after the spring change. Just installing the new leafs did not give me this much drop. I wanted 2 ", the new leafs gave me almost 1 1/2". Keep in mind, if the old leafs already had a couple leafs missing, the change change would be greater.

I eneded up making some longer shackles to get another 5/8" further drop. Know this, in order to get 5/8" drop from the shackles, I had make them 1 1/4" longer.
http://i1139.photobucket.com/albums/...k/102_2415.jpg

Re: 1957 Chevy truck re-rebuild
 

The new stance looks better. The new spring may settle a little over time.
Kim

Re: 1957 Chevy truck re-rebuild
 

Finally a picture of the truck!! Only kidding you do good work and explain it so even a Dumb azz like me can understand it. Keep the pictures coming of this I think it will be a fine example of TF Trucks . Lookin Good

Re: 1957 Chevy truck re-rebuild
 

Sweet looking truck! Keep the pics coming!!

Re: 1957 Chevy truck re-rebuild
 

I am chuckling on this end, does the "TF" mean Task Force?

Re: 1957 Chevy truck re-rebuild
 

Yep,that's what it means!! ;)

Re: 1957 Chevy truck re-rebuild
 

Great, I didn't know about the Task Force until a couple months ago.

I love watching old car commercials. I have some tapes and DVD's. One of the last DVD's I bought had a long commercial from 1957.

It was based on a fleet of 57 Chevy trucks making what's called the Alcan run. Had I not seen that, I would have no idea of the task Force. Good stuff.

Also, I'm glad you like my desciptive posts, I have a build thread for a Willys truck going also. It began as a showing thread and has turned into a teaching thread. It's been very satisfying. I suppose I've carried the same narrative writings to this thread also.

I didn't have these next pics loaded into photobucket before. Sorry to say, I'm on dial-up, it takes forever to load pics.

This picture is of the day we started working on it. Don't be fooled by how nice it looks. As I mentioned before, it was all redone years ago, it just wasn't properly redone.
http://i1139.photobucket.com/albums/...k/102_0575.jpg

I will say however, I am very fortunate to start with a truck that is complete.

My intent was to give dad one fun truck. Something that was everyday reliable, yet had an aggressve attitude and plenty of power to make him smile from ear to ear. He had a 327 that had issues, right here I've taken out the 327 and fitting a 396 in it's place.
http://i1139.photobucket.com/albums/...k/102_0596.jpg

Re: 1957 Chevy truck re-rebuild
 

The BB should give it plenty of get up and go.
Kim

Re: 1957 Chevy truck re-rebuild
 

Nice tail light mod and very nice truck. Thanks for posting pics and keep them coming.

Re: 1957 Chevy truck re-rebuild
 

Hi Kim57, definetly he would have liked the power of the Big Block. I was also hoping to give him a truck that when he opened the hood, the engine bay would have the visual impression he would be happy to show off.

Since dad was coming to visit during the beginning of the project, I was working on both the drivetrain and body work at the same time.

One reason was to give him a moment of excitement when he saw the progress. Plus he wanted to be a part of the work. He had his choice to work on body or engine, which he did both.
http://i1139.photobucket.com/albums/...k/102_0644.jpg

After checking and measuring and fitting and checking again, I finally settled on engine placement. When done, I had about an inch clearance from side to side and front to back.

The front, between the engine and radiator was a tight fit. I used an alternator and power steering brackety from a 1960's corvette. If I had used a newer, say 1970 or newer, the water pump and bracketry are moved forward about 3/4". I went to a dual electric fan, With the dual fan motors, the space between the two motors gave me an open area that the water pump pulley fits between. Altough a close fit, everything is still easy to work on.
http://i1139.photobucket.com/albums/...k/102_0645.jpg

More on the engine later.

One small detail I did to the bed was the same as many, I closed off the rolled edge of the top rail of the bed. Before I closed off the ends I extended them 3/4". Such a small addition, but it added something to the visual of the flow of the back of the bed.
http://i1139.photobucket.com/albums/...k/102_0664.jpg

I originally closed the ends, then I noticed from the side I could see into the edge of the top of the tailgate. It had an unfinished look, this was my remedy.

Re: 1957 Chevy truck re-rebuild
 

Looking good.
Kim

Re: 1957 Chevy truck re-rebuild
 

"Too Fine"
thanks for posting a pic of the truck
nice looking truck, good start for your project

Re: 1957 Chevy truck re-rebuild
 

Well, now that I think about it, it was amost 2 years ago to the day I took this picture. I had just got the engine assembled to this point when I got the call that dad passed away.
http://i1139.photobucket.com/albums/...102_0688-1.jpg

So the engine was 80 percent assembled, and much of the body work was smoothed. I lost my interest, my focus was gone. The truck sat for a year and a half. I had another truck that needed work so I worked on it and the 57 gathered dust.

Other than the pictures of the redesigned taillights that I posted earlier, all the others are from 2 years ago.

Now we're up do date, at least the last few months. This Chevy has become my only focus. Being single, I can do that without getting in trouble.:lol:

One issue I had was to go back to the original rear bumper, so I ordered one along with the original brackets.

I mounted the bumper then stood back and scratched my head. Are you kidding me, that thing sits so far back it doesn't look like a part of the truck. Plus it's too low.
http://i1139.photobucket.com/albums/...k/102_2581.jpg

I removed a section out of the brackets, then realized I wanted to build the filler panel between the bed and the bumper. I needed about 3/8" space. Welding a bead on the bead I bridged the space to hold the bumper in place while I made the panel. Now it's time to get the brackets back together.
http://i1139.photobucket.com/albums/...k/102_2676.jpg

Once the gap has been filled.
http://i1139.photobucket.com/albums/...k/102_2682.jpg

Time to get it looking original.
http://i1139.photobucket.com/albums/...k/102_2685.jpg

Looking good and the bumper is exactly where I want it to be.
http://i1139.photobucket.com/albums/...k/102_2693.jpg

Same procedure for the ones that go to the sides.
http://i1139.photobucket.com/albums/...k/102_2697.jpg

The welding and grinding is done.
http://i1139.photobucket.com/albums/...k/102_2704.jpg

Re: 1957 Chevy truck re-rebuild
 

You have some excellent welding skills and even better finishing skills. Looks great!

Re: 1957 Chevy truck re-rebuild
 

Looks real good.
Kim

Re: 1957 Chevy truck re-rebuild
 

Still looking at the rear of the truck, I'm gonna bring a picture of the filler panel between the bumper and bed.

http://i1139.photobucket.com/albums/...k/102_2710.jpg

Building the panel was one challenge. As I progressed I knew I had to mount it to the flat area just below the tailgate. I didn't want to just use bolts or screws to attach it to the bed. Looking at the picture above, you can see a couple spear like bars that come in from the sides.

If I used bolts or screws, I would have an indentation in the panel where the screws are tight against the panel.

I have a plan.....;) Starting with a piece of 3/4" tube, I cut it in half length wise. http://i1139.photobucket.com/albums/...k/102_2646.jpg

Using a cut off wheel on the 4 1/2" grinder, I cut 3" inward.
http://i1139.photobucket.com/albums/...k/102_2647.jpg

I put a small relief cut crossways at the end of the 3" cut. Then with a pair of pliars I sqeezed the ends together.
http://i1139.photobucket.com/albums/...k/102_2648.jpg

One together I stitch welded.
http://i1139.photobucket.com/albums/...k/102_2649.jpg

In the first picture above, you can see how after a little grinding I ended up with smooth spear ends.

I made 6 of these tabs for mounting. I welded 3 these to the under side of each of the spears. Then drilled the panel and the bed flat to match the screws on the spears. Now just tighten the nuts on the back side.
http://i1139.photobucket.com/albums/...k/102_2653.jpg

The nice thing about these mounting spears is the clamping force is distributed across a large area, now there is no bolt indentations.

Re: 1957 Chevy truck re-rebuild
 

Looks pretty cool There used to be a custom car show here once a year I really miss it!

Re: 1957 Chevy truck re-rebuild
 

Very nice.
Kim

Re: 1957 Chevy truck re-rebuild
 

Trying to cover the list of changes that Dad wanted, I remember he wanted "exhaust cut outs".

Ok. now we're stepping back into his teenage years, cut outs I thought, I was already concerned with how I'm gonna get the exhaust to fit since it looks like it's gonna run right into where I'd like the transmission crossmember to be.

By time I was done, I fulfilled his request. I believe I went above and beyond what he would have expected.

It started with the idea that I didn't want the tail pipes going out the back. Next, I don't like the sound of an 8 cylinder engine with the tailpipes coming out the sides of the vehicle. To me it sounds like 2 four cylinder engines since there is one bank of cylinders sounding from each side.

Well, I did do the tailpipes out the sides, I ran them right through the steps.
http://i1139.photobucket.com/albums/...k/102_2182.jpg

By time I finished the exhaust, wow, what a project. I solved the cut out issues, I have no pipes out the back and I took care of the 4 cylinder sound.
http://i1139.photobucket.com/albums/...k/102_2252.jpg

Re: 1957 Chevy truck re-rebuild
 

That should do the trick. Very nice.
Kim

Re: 1957 Chevy truck re-rebuild
 

I'm liking this build. Good work!

Re: 1957 Chevy truck re-rebuild
 

did you made the exhaust Tips your self ? or can you buy these somewhere ?
i like them

Sander,

Re: 1957 Chevy truck re-rebuild
 

what are the butterflies for?

Re: 1957 Chevy truck re-rebuild
 

Ohhh, I've started the truck, I've tested the exhaust, I'm so excited to drive it, maybe soon.

seanery, The butterflies are what makes the exhaust totally unique. In the old days, guys would run and exhaust to the mufflers, along the way, before the mufflers they would have a "Y" pipe. This extra outlet had a cap over it that was held in place with a couple of bolts. These are called cut outs. Once they got to the race track they would unbolt the caps and now the exhaust had a free flowing outlet. These were call "cut outs", the exhaust cut out before the mufflers.

63split, I found the exhaust tips in the Jegs catalog. I was very pleased with the design and how they were made.

Everybody else, thanks for checking in. The encouragement is always appreciated.;)

seanery, with these next pictures, you'll be able to follow the flow of the exhaust. I replaced the idea of using the old style of removing bolts to open the exhaust. Jegs has these electric powered butterflies that opens the exhaust cut outs by pushing a button. Also, instead of dumping the exhaust out under the truck, I made a bypass pipe that routes the cut out exhaust around the muffer and reconnects to the side outlets.

http://i1139.photobucket.com/albums/...k/102_2223.jpg
http://i1139.photobucket.com/albums/...k/102_2222.jpg
http://i1139.photobucket.com/albums/...k/102_2220.jpg

Due to the amount of space under these trucks I was able to fit this all together. With a car I'd be cramped to get this to fit.

Re: 1957 Chevy truck re-rebuild
 

thank you for the tip ! on the tips:metal:
nicely done on the total setup with the cutouts

i will use this one as an example on mine

thanks Sander,

Re: 1957 Chevy truck re-rebuild
 

very nicely done!