The Stovebolt Site Forums The Shop Area Making a Stovebolt Bed Custom Bed for my '53 3100

So after much research and contemplation, a plan has been devised for the bed on my '53 3100.

From the beginning I had some items I wanted...

1) Flat top rail so a had roll up bed cover can be installed.
2) Tailgate with a modern lockable latch
3) Custom tail lights
4) Use the existing heavy channel iron bumper

What I had to work with...

The entire floor of the existing bed was gone, only the heavily rusted rear cross sill remained, the two center and front cross sills were gone. The lower third of the front panel was rusted off. The bed angles were heavily rusted and there was some rust through of the bed sides at the bed angles. The tail gate was intact, but the lower roll was heavily pitted.

On a side note, the cab and front of the truck have hardly any rust at all. The truck was parked for years halfway under a shed, the front half out of the weather and the bed, with hay and feed sacks in it, was exposed to the weather.

The plan...

I purchased all the cross sills, stake pockets, angles and strips from Mar-K. A local sheet metal shop is going to make the bed sides and front panel. The bed sides will be reproductions of the originals with the top rail flat, instead of angled. The bed will end up being about 16" deep, instead of the approx. 14" original, because the flat tops with the side edge roll being at about the same location as original. The front panel will the similar to the original, just a bit taller to match the sides and the top will be broken square instead of rolled like the original.

The custom tail lights are still being considered. Right now the thought is to repurpose the existing bed's front stake pockets as extensions of the new rear stake pockets to provide space for mounting tail light assemblies from 73-79 F-100. (I know, Ford parts on a Chevy, I may burn for that one...LOL) My concern is how the lines and shape of the tail lights will work with the lines and shape of the bed. It must look like it belongs there...not just some junk bolted on.

We will wait to fabricate the tailgate after the bed is assembled. The plan is to make a double walled tailgate, so a latch assembly from a 99-07 chevy stepside can be used. The third brake light will be in the top center of the tailgate. The "CHEVROLET" in the original tailgate will be cut out and welded into the new tailgate, but lower and to the right, instead of centered.

Finally, the bumper will be modified a bit on each end, to curve around and meet the rear fenders on the sides. I am going to replace the running boards because the ends are rusted and the outside edges are bent, so the metal on the tops of the existing running boards will be used to fill in the space between the bumper and the back/sides of the bed, sort of making a step that appears similar the running boards.

Progress so far...

I used the sills, stake pockets, angles and strips (along with two 1x4's cut to 77" long) to mock up the bed layout on the frame of the truck. This allowed me to take measurements that I could not due to rusted away portions on the existing bed.

The existing bed is disassembled and measurements have been marked on a bed side and the front panel to be used as patterns by the sheet metal shop. All that is ready to go as soon as they tell me they are ready to do the work.

Other items...

I am trying to decide if I want to try to repair the fenders or purchase replacements. There is rust on both where they meet the running boards and both had a number or dents and edge dents.

The fuel tank is going to be relocated to inside the frame, behind the rear axle. I would like to locate the fuel filler in the driver side fender, behind the rear wheel. Still considering how to fabricate that.

I also plan to install side marker lights in the rear and front fenders. Considering 68-72 Chevy pickup side marker lamps for these.

I know this was long, if you made it to the end and still awake, congratulations! LOL

Tim

Tim, It reads like a great project. Lots-o-work, but should look cool when done. Check out moff's project. He made his own bed too. Not the same year or model as yours, but worth checking out.



https://www.stovebolt.com/ubbthreads/ubbthreads.php?ubb=showflat&Number=768999#Post768999

Take a look at this. http://s1148.photobucket.com/user/1...amp;_suid=141878281006808704103162437233 Scroll through the pic's and you can see progresion from plywood mockup to in primer ready for paint. It is a 1 ton so your bedsides are shorter. I did make mine a couple inches taller also and did a tailgate similar to what you are thinking. I ended up getting new fenders even though I had a pair that were probably better than what you describe. Mine are Dynacorn reproductions that I am very pleased with. Everything else you have will be new so might as well have everything from the cab back new. (My opinion)

Don't you just love it when a plan comes together.

Yesterday I dropped off a bed side and the rusted off bed front at my friend's sheet metal shop. Once he has the bed sides and front panel made, I will take the cross sills and stake pockets there for assembly. Possibly before New Years.

Also yesterday, the 1973-79 F100 tail lamp assemblies (that I had ordered Monday evening) arrived. The aftermarket pair was only $28 and free shipping. They did not include bulb sockets.

I was concerned about the depth of the light assemblies plus the Ford OEM style bulb sockets would be over 5 inches...and I don't have that much depth between the back of the truck and the stake pocket position. Remember, the goal here is to maintain the lines of the original bed and incorporate the tail light so it appears it is meant to be there.

At the local auto parts store this morning, I happily discovered that the 1989-96 GM Turn and Stop Socket (that has the wires coming out the back at a right angle) will twist and lock into the Ford housings. Two sockets for each housing (one for the stop/turn and the other for the backup light) They were $7 each and use a common 3157 bulb.

Now the total depth of the assembly, with sockets installed, is only 2.25 inches...which is very very close to the depth that will be available for them...won't know for sure until the new bed is assembled, but it looks like a perfect fit at this point.

My thinking is that the repurposed old front stake pockets, after the bed flanges are cut away, will be turned upside down (so they curve in at the bottom, rather than curve out) and welded in behind the rear stake pockets to be the enclosures for the new tail light housings. The contour of the Ford tail lights will then compliment the lines of the upside down stake pockets...and the curves and style will all match the truck.

That's the plan anyway...

Thanks for sharing the photos. I like that! Nice job!

Now that the holidays are over, I have done a little more work on the custom bed.

I made a cardboard mock-up of the tail light housings we are going to build from the old front stake pockets.

http://www.timjharrisphoto.com/53chevy3100/eafa95ad

After I had made the mock-up, all the latch parts for the tailgate arrived. I am using the latch parts from a 99-07 Chevrolet Stepside because the width of that tailgate is 49.0625", the '53 bed is 50" wide. This will allow for the sheet metal of the tail light housings to wrap inside the bed and weld up for both reinforcement and a clean appearance.

Also, after all the latch parts arrived, we laid them out and began working on plans for the custom tailgate. Following some discussion, we decided to not go with the original build from scratch idea, but try to find a 99-07 Chevrolet Stepside tailgate. It turned out to be easier to find, and a lot cheaper, than I had thought it would be.

The plan is now to cut the CHEVROLET out of the original '53 tailgate and weld it into the new 99-07 tailgate in a lower right position. Then it will just be a matter of trimming and fitting to make it function and look like it belongs there.

We also discussed putting the third brake light in the top center of the tailgate...I'm not totally sold on that idea yet.

So now I am just waiting on my sheet metal friend to say he is ready to stamp out and form the bed sides.

I like the taillights with the pocket flipped that way. It will be a nice fit although I would recess them if there was room, but apparently not.

The tail lights will be recessed so they are flush. The lens is taped to the cardboard mock-up in the photo to give an idea of how it will look.

Gotcha'. Nice.

My friend at the sheet metal shop finally got around to my project this morning and I went over to watch the bed sides being punched out and bent.

I added 5 photos to my gallery at www.timjharrisphoto.com/53chevy3100

We made plans to assemble the bed next Saturday morning.

It is good to see some progress on something that I have been planning for a long time.

Nice to have that kind of equipment available.

This past Saturday we welded the stake pockets to the custom bed sides and then welded the bed together. The front panel and bed sides were fabricated by my friend, the stake pockets and sills are from Mar-K.

The pipe ordered for the top outside edges of the bed sides did not arrive, so that will be the starting place for the next work on the bed. We are going to close up the triangle openings where the '53 stake pocket angles don't match the ninety degree bend of the custom bed sides.

The pipe will be in the same place, relative to the stake pockets, as it would be on an original '53 bed, the only real differences at this point from stock is the flat tops and everything is welded together instead of bolted. The big departure from a stock '53 bed will be the tail lights and tail gate, which are currently just drawings.

I added some photos to my gallery, link below.
Tim

Yesterday we were able to spend a few hours on the bed project. Welded the pipe on the top rails and did some planning for the tail light pockets.

The tail light pockets will be constructed out of front stake pockets purchased from Mar-K. We cut the stake pockets vertically and flattened out the flanges, leaving the beaded 90 degree bends. One half of the stake pocket will be welded (upside down) to the back of the rear stake pocket with the top notched and flush with the outside of the bed rail pipe. The other half (with a strip of flat metal added in between to increase width) will be welded to the back of the bed sides (which were extended by 1.675"). The a hole will be cut in the rear flange for the tail light, with a box welded inside to support the light. Got all that? LOL

We are using tail lights from a 78 Ford F150. I sure hope lightning does not strike me for that part.

Our next work day is planned for 3/21.

Still seems very interesting in design. Anxious to see pics when available especially how the taillight build goes. You also seem to be using an actual spot welder for all your welds. Nice and clean.

My friend has a heavy duty pinch welder at his shop. It was interesting to learn it uses compressed air to press the pinch and it is water cooled. He says they don't use it much anymore. We used it to weld the stake pockets and the bed angles onto the bed sides. That pinch welder was actually fun to use.

The cross members and the front panel were mig welded.

If everything works out, we will be working on it again on the 21st.

We didn't get back to working on the bed until Saturday the 28th and our time was somewhat limited.

We made and welded in the gussets that filled the gaps between the tops of the 53 stake pockets (that are for the angled top rail) and the new flat top rail.

The tail light pockets were fabricated from a cardboard mock up I had made. The hole for the tail light lens has to be cut out and then the assembly welded together and onto the bed.

I had also made a cardboard mock up of the tailgate. We took some final measurements. We will build it on the next work day.

Hopefully we will be able to get back to it on Friday. If all goes well, we may complete the bed project that day.

It has been a while since I updated about the custom bed. A few Saturdays passed before we were able to work on it again. On May 2nd, we punched out and bent the tailgate. Unfortunately, I neglected to take any photos of that, will have to get some next time. Out next planned work day is May 30th. The plan is to weld the tailgate together and weld in the tail light pockets.

Today, I am cutting out the CHEVROLET from the original tailgate so it can be welded into the new tailgate tomorrow. We decided to set the CHEVROLET low and to the right on the new tailgate. The back end of the bed is going to be so different from original with the built in tail lights that we thought there was no harm in making another change. LOL

The tailgate was welded together this morning. I added a few photos to may gallery. It might be a few weeks before we can get back together to work on the bed again. June 15th will mark 6 months on this portion of the truck project.

Purist may cringe, but considering all the custom work on your truck , I really think it is neat. Nice modern styling using an old world piece.

If you ever saw artist/carpenter Jimmy Diresta on tv or You Tube, he made a custom tailgate cover for his '68 C10 that reads his name,"Diresta". Just another custom idea.

Progress has been slow on the bed lately because we have been so busy with other things.

This week we did make some progress on the taillight pockets. The custom holes for the lenses are now milled out to accept the taillights, the pockets we fabricated a few months ago are ready to be welded together and then welded onto the bed.

After those are on, the last fabrication item are the brackets for the tailgate hinges and then box off the bottom of back below the tailgate.

The metal shop is then going to have one of their employees clean up all the welds, blast the bed and tailgate and the prime it all with PPG epoxy primer.

After we fit it on the truck, we will mock up the alterations to the original steel 4" C-channel bumper to have a clean appearance with the bed. This will include some added strength so a hitch receiver can be welded underneath the bumper and a metal backing plate where the license plate will mount.

A friend from out of town recently visited and I showed him the bare metal cab, sitting on the frame in my barn. He commented that it was odd that I had started with the bed in my resto-mod. I laughed and told him I was starting at the back and working my way to the front. LOL

Tim, I have been following this bed build and as I've said before, I am impressed with your ideas for modification and most certainly with the quality and skill of your fabricator as evident in your pictures. I think you will be hard pressed to complete the cab in a way to compliment the bed.

We were able to get back to working on the bed Saturday. I have added 15 photos to the gallery (link below) of our progress.

We assembled the tail light pockets and welded them onto the bed. The pockets are made of two pieces. The outer piece was fabricated from a Mar-K stake pocket, split in half and turned upside down. The inner piece was fabricated in the shop for the tail light to mount recessed just as it did in it's stock Ford application.

I have been asked why I went with '78 Ford F-series tail lights on a 53 Chevrolet 3100. Well, after looking at just about every tail light available, the Ford was selected because the outside curve of the tail light very closely matched the outside curve of the stake pockets, so it blends better with the style of the truck...in my opinion. I have been told that I will be struck by lightning for putting Ford parts on a Chevy. LOL

Then we fabricated mounts for the tail gate hinges. The hinges we used are from 1990's Chevrolet pickups. We installed a piece of pipe, inside, across the bottom of the tailgate, the correct size to pivot on the hinges. The pipe was notched on the right side to allow for the tailgate to be lifted off, just like a modern pickup tailgate.

We used a square bar across the top and two pipe clamps to hold the tailgate in position in order to determine the locations for the hinge brackets. Once it was all tacked on, we removed the bar and clamps to test the operation of the tailgate. It opened and closed very smoothly...so smoothly that we were surprised at how well it worked.

There was a bit of grinding necessary to get the tailgate removal to function smoothly. Our tolerances were so close that as the tailgate was tilted to remove it, there was some metal contact. A little precise grinding in the right spots and that minor issue was resolved.

Then we installed the tail lights just to see how it all looked together and take a few photos.

That's all we got done before time ran out. Granddaughter coming to visit trumps truck bed. LOL

The tailgate still needs vertical pieces to be fabricated and welded on the outside edges. These will close against the back of the bed edges, functioning as a stop when closed and also make a clean appearance across the back of the truck.

We also have a few spaces to close up and then pan off the area below the tailgate. The dress grinding, blasting and primer.

As we were working on Saturday, we discussed that it has been almost a year since we initiated this project. The design began last November. While it has taken a while, we all agreed that the time allowed us to think the project through and make a number of small changes that have greatly improved the results.

Questions and Comments are always enjoyed. I am having a great time working on this project and always happy to share.

Nice! Taillights blend very well I think.

One of the original ideas was to have a third brake light on the tailgate. I have yet to find a light that is slim enough to fit and not look like it was just an afterthought slapped on there.

Here is an overdue update on the bed build.

The bed is complete and will be blasted/primed tomorrow (Tuesday, Feb 8).

The Saturday before last, we welded on the last two pieces. Those were a trim piece under the tailgate and a small strip to close the gap between the bed floor and the tailgate.

We also installed the tailgate latches. For a clean look on the outside of the bed and tailgate, the latch brackets were welded instead of using bolts. It is a universal stepside tailgate latch kit that I picked up at a swap meet last year.

I'll have some photos to update within the next few days.

I can't wait to get it home, bolt on the fenders and set it on the truck!

The metal work on the custom bed has been completed, blasted and primed. It is now at my shop.

Lots of new pics in the gallery (link below).