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The Vandal. 1957 "Big glass" 3100 restomod.
Four years ago, I started this restomod project. I had a build thread on another forum, which was destroyed by photo bucket, so I quit updating it. I just resumed working on this truck after a 9 month break. I'm excited to be working on it again, and posting updates. It will take me a while to upload pictures and piece together this build thread. Some of it may be out of order.
The details: 5.3/4L60e. Nova sub-frame. C4 IRS. C5 brakes. C6 wheels. When I brought this truck home, I found a parking ticket dated 1978 from the University of Idaho aka the "Vandals". And the name stuck... The day I drug it home: https://farm2.staticflickr.com/1897/...e7749867_c.jpg It had a Nova sub-frame tack welded under the original frame. I cut that mess off, and spliced the sub-frame into the truck frame. https://farm2.staticflickr.com/1855/...7cfdbb8f_c.jpg https://farm2.staticflickr.com/1856/...54568859_c.jpg https://farm2.staticflickr.com/1880/...c216327c_c.jpg Then I had to finish out the front frame horns to mount the bumper and radiator support: https://farm5.staticflickr.com/4570/...741844b6_c.jpg https://farm5.staticflickr.com/4567/...a4d66ecc_c.jpg https://farm5.staticflickr.com/4554/...5197d073_c.jpg https://farm5.staticflickr.com/4538/...86d38283_c.jpg -continued- |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Looks like another sweet build....more,more,more....
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
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When I bought it, I thought it was a Gen2 camaro sub frame. The first set of coil over shocks I bought didn't fit. After a little investigating, I discovered it was a Nova, and not a Camaro. Nova frames have less suspension travel. Then, I bought RideTech coil overs. They were still too tall. Long story short... I ended up raising the upper shock mounts to fit a taller shock. https://farm2.staticflickr.com/1862/...1abb52c8_c.jpg https://farm2.staticflickr.com/1874/...a8e09eef_c.jpg Next, Kore3 billet hubs w/C5 calipers. These things are a work of art! https://farm2.staticflickr.com/1860/...38e1c3be_c.jpg https://farm2.staticflickr.com/1851/...c9404172_c.jpg I Powder coated the spindles silver, and calipers gloss black. https://farm2.staticflickr.com/1882/...b85f7d3a_c.jpg https://farm2.staticflickr.com/1896/...5d0931d8_c.jpg https://farm2.staticflickr.com/1866/...902df5e5_c.jpg Speedtech control arms, and Ridetech coil overs to finish the front end. https://farm2.staticflickr.com/1861/...5f7faa0a_c.jpg https://farm2.staticflickr.com/1851/...aedba414_c.jpg https://farm2.staticflickr.com/1868/...a28631df_c.jpg -more to come, later- |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Made a dolly to move the cab and flip it.
https://farm2.staticflickr.com/1868/...e28cb0c4_c.jpg Floor pan repair https://farm2.staticflickr.com/1847/...862b1dcb_c.jpg https://farm2.staticflickr.com/1896/...debd4c4e_c.jpg Modify the firewall for brake booster: https://farm2.staticflickr.com/1848/...4f0962b3_c.jpg https://farm2.staticflickr.com/1863/...e160eeb5_c.jpg https://farm2.staticflickr.com/1877/...f8f581e3_c.jpg https://farm2.staticflickr.com/1849/...66db894b_c.jpg https://farm2.staticflickr.com/1886/...69263690_c.jpg Home built bracket for the brake pedal. https://farm2.staticflickr.com/1852/...665569a2_c.jpg https://farm2.staticflickr.com/1895/...da3e1b8c_c.jpg Mounting the dbw gas pedal: https://farm2.staticflickr.com/1852/...d33bf28a_c.jpg https://farm2.staticflickr.com/1867/...61e7eae9_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
outstanding fab work, I like the work to graft the old frame to the clip especially
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
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Next up, sheet metal repair. Cutting off the door skin. https://farm2.staticflickr.com/1891/...1e42acac_c.jpg Starting with a flat piece of 18g, let's make new door bottoms. https://farm2.staticflickr.com/1844/...92819281_c.jpg https://farm2.staticflickr.com/1897/...2fb6246e_c.jpg https://farm2.staticflickr.com/1891/...6f185044_c.jpg https://farm2.staticflickr.com/1856/...52fe6b40_c.jpg https://farm2.staticflickr.com/1872/...e89e4bff_c.jpg https://farm2.staticflickr.com/1894/...ffa4cb22_c.jpg https://farm2.staticflickr.com/1845/...6bc61dbd_c.jpg https://farm2.staticflickr.com/1891/...7ed009fb_c.jpg https://farm2.staticflickr.com/1847/...8a6297d6_c.jpg https://farm2.staticflickr.com/1866/...3ddd55a6_c.jpg https://farm2.staticflickr.com/1843/...8b2f8f5a_c.jpg I made a new door skin on the english wheel. Welding in place with my dad's TIG welder. https://farm2.staticflickr.com/1846/...eb35a116_c.jpg https://farm2.staticflickr.com/1882/...c4f045e4_c.jpg Repeat on the other side: https://farm2.staticflickr.com/1876/...68ea1085_c.jpg Tired of borrowing my dad's welders, I bought this bad a$$ little machine: https://farm2.staticflickr.com/1854/...685bf65d_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Fender repair. I bent up some patch panels from the door skins of another car that I parted out. TIG welded in place with the new MM215.
https://farm2.staticflickr.com/1860/...a49d0083_c.jpg The upper fender mounts on both fenders were rotted out. Shaped up some new pieces and welded in place. https://farm2.staticflickr.com/1898/...0828ec5f_c.jpg https://farm2.staticflickr.com/1849/...d976d473_c.jpg https://farm2.staticflickr.com/1895/...af6033ab_c.jpg https://farm2.staticflickr.com/1845/...e8e00686_c.jpg And finally, some assembled shots for those still following! https://farm5.staticflickr.com/4528/...56363494_c.jpg https://farm5.staticflickr.com/4563/...bddc01c7_c.jpg https://farm5.staticflickr.com/4521/...8252c47b_c.jpg https://farm2.staticflickr.com/1895/...71b052e0_c.jpg https://farm2.staticflickr.com/1875/...762810af_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
You've done some great work, looking forward for you to catch us up to date...Jim
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
Wonderful fab work. You must spend every waking second in the shop! The way you did the flat spot for the PB Booster is a particularly nice touch.
QUESTION: What did you do to address the rust inside the doors you repaired? |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Thanks, guys. Dan, all the bad rust was cut out and replaced with new metal. While the door skin was off, I blasted the surface rust off the inside of the doors, where I could get to. I followed up with a wire wheel in the drill, and sanding with a die grinder. Then I brushed on Oshpo, and covered it with a butyl sound damper.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
I milled a steering column mount on my dad's bridgeport.
https://farm2.staticflickr.com/1884/...eebc80a4_c.jpg https://farm2.staticflickr.com/1854/...4b835e8d_c.jpg https://farm2.staticflickr.com/1841/...e76632fd_c.jpg Welded in a new fender cap. https://farm2.staticflickr.com/1845/...abddf5cd_c.jpg https://farm2.staticflickr.com/1850/...7404d6f4_c.jpg https://farm2.staticflickr.com/1863/...cfc27687_c.jpg I replaced the cab steps. The rocker panels did not meet my standards. https://farm2.staticflickr.com/1852/...8b26b89c_c.jpg I bent up a sample of what the rocker shape should be per the assembly manual. (compared to the reproduction piece) https://farm2.staticflickr.com/1859/...d3e1327d_c.jpg So... I cut them off and made my own. That was WAY too much work without a sheet metal brake. https://farm2.staticflickr.com/1885/...25097d97_c.jpg Next, I made the fenders fit the radius of the door. Before: https://farm2.staticflickr.com/1868/...a8550206_c.jpg Open up the flange, and stretch out the area in the red triangle: https://farm2.staticflickr.com/1885/...2851360a_c.jpg After: https://farm2.staticflickr.com/1874/...4a42f38a_c.jpg After gapping the doors/hood/fender: https://farm2.staticflickr.com/1892/...74a7d59d_c.jpg Repeat everything on the other side: https://farm2.staticflickr.com/1876/...aed031ff_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Then I made a column mount for a shift cable.
https://farm2.staticflickr.com/1872/...840bee0f_c.jpg Here's a shot of slicing the door jamb to fit the bear claw latch. https://farm2.staticflickr.com/1875/...29938c93_c.jpg And we're off to the blaster! Back from media blast: https://farm2.staticflickr.com/1841/...41bf08ea_c.jpg https://farm2.staticflickr.com/1870/...a3707ef3_c.jpg https://farm2.staticflickr.com/1862/...40fc9592_c.jpg A little acupuncture therapy with the stud gun: https://farm2.staticflickr.com/1848/...6e998b16_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
After returning from the blaster, the underside and cowls got 2 coats of SPI epoxy.
https://farm2.staticflickr.com/1852/...cde5dcc2_c.jpg Followed by welding in the cab corners: https://farm2.staticflickr.com/1873/...1a74818b_c.jpg https://farm2.staticflickr.com/1884/...43859d10_c.jpg Then the underside got coated with SPI bedliner (now discontinued) https://farm2.staticflickr.com/1894/...74264935_c.jpg https://farm2.staticflickr.com/1842/...2e2161be_c.jpg After painting the inside with 2 coats of SPI white epoxy, the Restomod A/C unit was fitted. https://farm2.staticflickr.com/1870/...a5050f2a_c.jpg Kick panel rust repair: https://farm2.staticflickr.com/1858/...f9facab1_c.jpg Cut out for speaker: https://farm2.staticflickr.com/1875/...9b8d87de_c.jpg I made a steel plate and tapped it for mounting Image Dynamics 5x7 speakers. https://farm2.staticflickr.com/1888/...7e382b40_c.jpg https://farm2.staticflickr.com/1883/...02cf46e1_c.jpg https://farm2.staticflickr.com/1861/...b9226b59_c.jpg And then welded the cowl panels back on https://farm2.staticflickr.com/1880/...4e4d2888_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
very nice work...
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
Everything looks really good. Nice detail on dealing with the rust inside the door. Wouldn’t some kind of paint inside the door after blasting have been easier than applying some kind of butyl material?
PS: Do you plan to leave the dash stock? I ask because I did and I now wish I’d smoothed the entire thing, possibly with the exception of leaving the stock radio holes. The glove box is unusable for anything once AC is installed. The Vintage Air controller could be put anywhere. No need for the ashtray, etc. Just an idea. I WAS going to put a ‘55 Belair dash in it but didn’t end up doing it due to cost - I was not doing the work myself. It’s an expensive wall hanger in my garage now...but they say you’re never done. I may install it one day! |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
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Paint Over Rust products will fail over time due to adhesion issues on rust. Because you can't get into every nook and cranny to completely clean out surface rust, epoxy will also fail. Once these coatings start to lift, moisture can wick under neath and rust will continue to grow at an accelerated rate. My solution may not be the right way, but I think it will be adequate, and better than most restoration practices. It is nearly impossible to access all areas of the inside of the door. What you see, is only surface rust. This is before Oshpo. https://farm2.staticflickr.com/1875/...88c69314_c.jpg Ospho is a phosphoric acid treatment. Acid treatments are a no-no for use under epoxy, unless it is properly rinsed and removed. Again, this is too hard to do inside a door, so the best solution is not use any kind of paint coating. For sound damping, I'm using full membrane sheets, which according to the manufacture, are a moisture barrier. https://www.sounddeadenershowdown.co...cts/cld-sheets I have used butyl tape products before on other projects, and over time, the heat slightly melts them onto the surface. Though, I have never used this exact product before, I assume it will work the same. The door bottoms were not welded in, until I was done working inside the doors. Here is a shot with the CLD sheet installed inside the door skin. https://farm2.staticflickr.com/1872/...ca2e736e_c.jpg And the last line of defense to coat the edge seams that didn't get opened, is Cavity Wax. The cavity wax flows into the seams, to protect rust from growing. Also, all new metal that was welded in, got the back side and seam coated with epoxy. It will never rust. https://www.tat-co.com/Products/Repa...r-Rustproofing I'm leaving the dash somewhat stock look. I deleted the heater controls, and made a cover plate from another ash tray. The A/C controls will be placed where the throttle/choke/lighter used to be. https://www.restomodair.com/shopprod...-a-c-controls/ . I might change the knobs with the stock knobs to give it an original look. The ash tray will hold a usb port plugged into the Retrosound radio. You're right about the glove box. I haven't solved that problem yet. I bought a shorty glove box from Restomod / Classic Air. With the glove box in place, I can't hook up the the ducts to the A/C unit. With the A/C unit in place, I cant get the glove box in. :( I will have to custom make my own glove box. That can wait until I get the truck running! (Because they're never done) :lol: |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Thanks for the link to the Restomod site. I had never seen that before.
I am wondering if their controls can be made to work with my already-installed Vintage Air system? If so I’d install them as you suggested in the locations of the factory top three knobs. Then I’d have to get a closure plate for the factory heater control location and have it color matched to my paint OR bite the more expensive bullet and weld that shut along with the ashtray and respray the dash. You’re right, they’re NEVER done! Oh well, that’s the fun (and the agony) of them! |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Dan, I think your best option would be using the Vintage air controls.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
Dude you're clipping right along. Strong work. Back in the dark web of my mind I seem to recall that you have an additional big window cab on hand. If so would you part with it?
Thanks Nut Case |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
staggering work. those 6x9s in the cowl are gonna booma boom boom with all that room, and an equal part of the sound is going to come out of the wiper cowl, so the whole neighborhood can jam too.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
Next order of business was to fill the gas hole
https://farm2.staticflickr.com/1892/...e7594bd1_c.jpg Finish weld the steps, and seam seal. https://farm2.staticflickr.com/1885/...16c81cfe_c.jpg Epoxy time! https://farm2.staticflickr.com/1847/...945149fb_c.jpg https://farm2.staticflickr.com/1842/...74299ded_c.jpg https://farm2.staticflickr.com/1876/...1ec8d118_c.jpg https://farm2.staticflickr.com/1875/...16605003_c.jpg Installed a battery box before mounting the cab FOR THE LAST TIME! https://farm2.staticflickr.com/1874/...9c0f7a37_c.jpg Cab mounted for THE LAST TIME! :metal: https://farm2.staticflickr.com/1872/...3ffabf5a_c.jpg https://farm2.staticflickr.com/1864/...da49e2e0_c.jpg https://farm2.staticflickr.com/1897/...c06bac5a_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Seat belts. For the lap belts, I made anchors out of 1/4" plate. Welded grade 8 nuts.
https://farm2.staticflickr.com/1847/...17e72626_c.jpg Plug welded from the inside: https://farm2.staticflickr.com/1884/...067c94cb_c.jpg From the under side: https://farm2.staticflickr.com/1892/...b2a855df_c.jpg For the shoulder belts, I made similar anchor plates: https://farm2.staticflickr.com/1842/...47869abc_c.jpg I attached a piece of welding wire and fished them up into the B pillars: https://farm2.staticflickr.com/1858/...0c901b7d_c.jpg Plug welded in place. You can see I had to drill a hole to run the fish wire: https://farm2.staticflickr.com/1857/...f0ff42f7_c.jpg https://farm2.staticflickr.com/1841/...a26f75a7_c.jpg https://farm2.staticflickr.com/1887/...b6dd4c86_c.jpg Inner fenders... They were hacked by previous owner with acetylene torch. I went through the trouble of patching in multiple pieces. I guess I like to TIG weld... Should have bought new one. https://farm2.staticflickr.com/1890/...6c8e07f3_c.jpg Installed: https://farm2.staticflickr.com/1879/...0de249d6_c.jpg Patched the fender badge holes with the TIG welder. I love welding with this setup. Miller 215, w/ CK #9 flex torch, SSC pedal, 040" tungsten. https://farm2.staticflickr.com/1873/...c4bf9115_c.jpg A little bit of file and metal finish. https://farm2.staticflickr.com/1896/...52d0e04c_c.jpg . . . . . Here's a shot from last week! You're now up to date, minus the door latch mods. https://farm2.staticflickr.com/1877/...894b85ea_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
image dynamics and zapco, sounds like you are an old school car audio guy too. I had a zapco 500.1 mono about 20 years ago, bought it from a dead stock store closing, so it was at least 5 years old then. zeff stuff is amazing quality.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
I dabbled in car audio back in 1990-1994. One of my neighbors had an audio shop, and I hung out to learn what I could. Did a lot of free installs and sub boxes for friends. Back then, I couldn't afford the "high end" stuff. I had Profile amps and subs, RockfordFosgate components, MTX electronic crossover. I'm just starting to get back into it. I want to hurry up and get this truck painted, just so I can do the audio install!
Door latch mods. My dad had an extra set of generic bear claw latches that I decided to use. I'll start by saying, I will never do this again. Next build (if ever), I will cut some out from a modern car in the junk yard, like a honda civic. Two reasons I did not use the altman latches. 1 - the price $$$. 2 - I don't like how the striker bolt sticks out that far from the jamb. So, me being me, I had to re-invent the wheel and do it my way. Bear claws do not have a lever for external door handles. With lots of errors... I finally came up with a lever that trips the release mechanism. https://farm2.staticflickr.com/1851/...cac618de_c.jpg Viewed from the top, the new lever is the bent one, which hits the release mechanism. https://farm2.staticflickr.com/1861/...55def071_c.jpg From this side, the external handle button hits the pad on the new lever. https://farm2.staticflickr.com/1894/...a6b1260a_c.jpg I had to modify the leverage ratio and location of this lever to hook up to the stock inside handle pull. https://farm2.staticflickr.com/1842/...bcabff9a_c.jpg Installed: https://farm2.staticflickr.com/1865/...05688c9b_c.jpg Note, there is a cable hanging out the opening. That attaches to the stock rod, to manually pull the door lock mechanism any time the inside handle is pulled. This activates the electric lock solenoid which triggers the other door. So, opening either door from the inside will unlock both doors. https://farm2.staticflickr.com/1845/...e765a47e_c.jpg There is an electric solenoid mounted to a bracket inside the door. https://farm2.staticflickr.com/1870/...d55a8ab5_c.jpg Here, you can see the other end of the cable that manually un-locks the door. https://farm2.staticflickr.com/1863/...d8f7d5ec_c.jpg I feel that these door latches SHOULD be locked when driving. They are way too sensitive, and will trip if hit hard. Therefore why I chose to use electric locks. The hot rod vendors sell electric lock kits that cost a fortune. The better alternative is to buy a car alarm that can activate electric locks. They can be had for $45-$75, and you have the benefit of an alarm system, and anti-theft options. When the vehicle is shifted into DRIVE, the electric locks activate. To unlock from the outside, simply push a button on the key fob. To unlock from the inside, pull the handle. Once the truck is done and driving, I want to design a system that will also LOCK the doors via pushing the inside door handles forward. I have designed it on paper, but don't have time right now to engineer it and make it work. Basically it will use a second set of door lock actuators in a push/pull configuration to move the door handle forward to lock. These are the actuators I used. When one is manually moved, it will trigger all four. https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Next, I had to cut out an area for the door panels to fit over the protruding latches. Leaving a little bit of material to cover the front side.
https://farm2.staticflickr.com/1887/...fede1565_c.jpg There is a little gap between the latch and the panel. https://farm2.staticflickr.com/1896/...e8cdef71_c.jpg A piece of sheet metal was added to the inside as filler, and stiffen the panel where it meets the latch. https://farm2.staticflickr.com/1893/...a1daa742_c.jpg Trimmed and added a welded bead to the edge. https://farm2.staticflickr.com/1852/...db6f5fcc_c.jpg Finished: https://farm2.staticflickr.com/1897/...bf4ed21a_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Very nice work!
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
good googly moogly thats some fine fabricating
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
Fantastic work!
-Joe |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
very nice, Ive been putting off the bear claws, but Iam rapidly coming to that point in my build that I have to do them.... I too have a hard time paying $350 for altman.... still not sure which way to go yet ... but I will have to decide in the next few weeks... You did a great job.. looks great
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
um....is that a small scratch in the finish.....? lol.
nice fab work! I, like you next time, will probably modify something from a modern vehicle that already has provisions for all the door handles, power locks, external key activation, interior door lock spindle etc. if I am going to modify something I want it to be something easily sourced at a wrecker. i would modify the truck around the new part. thats just me though. |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
Thanks for the comments!
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Meanwhile, with that said... I was looking at how bad of shape my bed is. I ordered a new bed from Mar-K during their recent sale. This project has gone on long enough, and it's time to get it done. I have nothing to prove by spending 3+ months fixing the old bed. In this case, $ wins over time. Otherwise, I have made no progress on the truck. |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
thats a pretty good idea with the welding wire for fishin it back up the window post, the inner fenders came out nice bud.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
For the most part, yes. The claws come with a mounting bracket. I relocated the holes so the claws dont stick out when they're open. Then shaped them to mount on the door.
https://farm2.staticflickr.com/1894/...a8b7d285_c.jpg I had to clearance the door. Added 1/4-20 rivnuts for the mounts. https://farm2.staticflickr.com/1855/...56c39b6b_c.jpg Another pic installed: https://farm2.staticflickr.com/1841/...c6c5ccee_c.jpg Give me a few days, and I will add pictures of the door jamb mods on the cab. Browse around your local pick and pull. All door latches are bear claw type, and will have an external trigger. You will have to custom fit a mounting bracket, anyway. These are what I was going to buy until my dad offered up this set. They don't have an external trigger, either. http://www.hotrodlatches.com/default.asp |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
You my friend are good!!!
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Re: The Vandal. 1957 "Big glass" 3100 restomod.
Thanks!
Here's the door jamb mods: https://farm2.staticflickr.com/1844/...364ae6db_c.jpg https://farm2.staticflickr.com/1872/...26389f77_c.jpg |
Re: The Vandal. 1957 "Big glass" 3100 restomod.
I got to go hang out and see this truck in person, it looks good up close too. Glad I got to come meet you and talk shop for a while...
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