The Stovebolt Site Forums Welcome! Welcome Centre Do It Yourself (DITY) Gallery 1958 Chevy Apache - Stella - "Start to finish w/upgrades"

Glad to hear she's got a name! I like it. I added it to the titles here and your signature line.

When you were taking care of some of those *other* problems, you at least had plenty of time to soak down some bolts.

A friend stopped by today to help get the rear fenders off. I had prepared by cutting slots in all the carriage bolts for a large screwdriver. The drivers side had a bit of rust which will require a new fender flange for most the fender. Will need to patch the bed side as well. Passenger side looked good.

I pulled the gas tank earlier in the day. The strap bolts snapped off like dry twigs. Will likely drill out the screws and retap the capture nuts.

Started removing the firewall sound proofing. Nasty stuff tarred to the floor pan. This will be one of those jobs to work on when i have nothing else to do. 30 minutes of scraping is enough to lose motivation.

I managed to remove the tail lights and brackets as well.

Been a pretty busy day.

You've got a lot done in just one month. At this rate your 3 year time estimate will be cut in half, at least.

Since I’m still waiting for tractor front end parts to arrive, i spent some quality time with Stella. With some reassurance from the body and paint forum, i decided to use the tools i had to remove a few bedside to crossbrace welds. My cheapo dremmel has been a real friend helping to remove at least 90 some bolts from the bed wood, steps and fenders. I used my last cutting wheel to remove two welds that held the back of the bed together. Its bout ready to lift off for final disassembly. I think I’ll invest in a more powerful dremmel and a hadfull of new cutting discs. Its slow but very precise and makes little to no mess.

After the bed is off, my next target is the skanky farmyard style trailer hitch. Its gotta go. Stella’s years of hard work are over, so she won’t need it.

About time for an update. The bed is finally off Stella 😁. Took some doing working alone. The below tailgate cross brace is damaged more than expected and will be fun straightening the heavy ga metal.

Found an unusual shim tucked back under the drivers side panel at the crossbrace. Cant seem to find it on the parts diagram. I also dug a can full of Great Stuff foam insulation out of a rear cab corner.

Planning to visit a somewhat local machine shop about the motor the came home with Stella. A very ordinary 350 that has been previously bored .030. My first inspection revealed cyl 1,3,5,and 7 are in real good condition. No ridge whatsoever. Considering something along the lines of the Jeff Smith 400 hp build.

Next up are the front fenders and then front and rear glass.

You sure are doing a good job with this story on Stella. Really good images.

Been slackin of late. Health seems to slow me down lately. Been catching up on clearing broken bolts out of keeper nuts from the gas tank straps. Found more stuff to fix. The frame flanges have some damage behind the cab. 😮‍💨 Will need to check the complete frame and make repairs once the cab comes off. As far as i can tell, Stella has been crashed at least two times.

I admit to being a slacker. I actually got back to almost finishing Stellas teardown for the first time since November. I decided to pull the final front fender and get her down to just a cab on frame. I did finish my welding class, purchased a used Mig/gas setup and an 80 gallon compressor. I’m one valve and circuit breaker away from having the compressor installed. I just need to change the oil so i can run in cold weather. I also ordered my first 8 patch panels to rebuild the drivers side from the rear cab corner to the front cowl. I need to install some in-cab bracing, pull the door, then remove the step/rocker, followed by the outer, then inner cab corners and rear pilar. Once the rear panels are all tacked in, i move to the front pilar inner/outer and lower cowl. I will photo the progress. I’m sure it will be slow.

I have been helping a friend with his 50gmc 1 ton with many of the same issues. The experience has been a great confidence builder.

The weather has taken a hard turn into winter in central Illinois. Fortunately Stella and all her parts are tucked away in dry locations. Rumors say single digits will slow me down even further for a few weeks.

The good news is i received a box of body panels yesterday which are for the drivers side lower cab. All came well packaged, no damage. Once i verify fitment, i plan to order the passenger side. This could prove to be a good cold weather task. I attached pics of two out of 8 panels i received. The largest was the inner step/rocker. The pics are two of the smaller panels. Will include pics of others later as i start slicing and dicing.

The last remaining front fender disassembly has been fighting me. I’m back to cutting screws and bolts with my dremmel cutoff wheel. This to is coming to an end. After this final fender, only door and cab bolts remain to give me fits.

It’s been a while since i have spent quality time with Stella. Installed bracing today to prepare for surgery. Rocker/step, front and rear pilars, lower cowel and cab corner are all up for replacement.

Wow! This looks like it'll be some surgery.

The first 20 spot welds are drilled out on the step. Only 40 to go.

44 spot welds and 2 torch welds removed to get this step out. The video must have been too big to post.

Kevin, UBB settings doesn't support videos. If you have hosted it somewhere, you can put a link to it. ~ Peggy

Stella received some much needed attention today. I trimmed the step/rocker to fit the existing slot. The fit is just where i want it. Fitting it now helps assure my gaps will be correct after I install all the vertical patch panels. Next i removed spot welds for the outer cab corner where it attaches to the pillar and the inner cab corner. Lots of finagling on getting to all the spot welds. The next task is to cut and remove the pillar to give access to inner cab corner repairs. Another 5 hour day and I’m exhausted.

I finally had the opportunity to start the first metal repair on Stella. After removing the rotted door pillar and inner cab corner tab, the support brace was exposed so i could drill out the rot and weld in a patch. Was good to finally start putting new metal back in. Now i need to finish removing the rest of the rot from the inner cab corner and install new cab corner and door pillar patch panels.

Had some time to install the door pillar patch panel and the inner cab corner filler. The process is slow as i need to aquire tools as i go. I set the step in place to verify fitment and all my door opening dimensions. Next comes a partial inner cab corner panel and the outer cab corner.

I like how you have prepared everything for body repairs. You have reminded me of steps I have seen elsewhere, but would probably have forgotten.
I have a ‘50 3100 that I am in the “tear it apart stage” of a frame up restoration. When I tackle the cab repairs, you’ve reminded me that I need to have the cab bolted back to the frame, and the door openings braced to maintain integrity before I start cutting into the rusty bits.
Thanks for taking the time to document your truck project. It may help you, but it really helps us.

Thanks Paul. I learned from countless youtube videos where the person making the repair video would say. I wished i had braced the door opening before cutting steps, rockers pillars. I will do the bracing a little different on the passenger side to avoid interferences with disassembly and welding new panels in. I had to repair the drivers side inner cab corner rather than replacing the entire patch panel because of my floor brace choice. Live and learn.

Its been a long 6 months with no real activity on Stella. The marginal fit of the rear cab corner left me scratching my head as to a path forward. I finally jumped into it today and finish cut the panel to fit and tacked it in place along the match line. The only remaining mismatch is in the lower right where the new panel tacks to the cab along the original cut line. I have decided to massage that body line into place after i finish the weld line and all the plug welds. Worst case, i cut it, reshape and weld it up.

I previously sanded and primed the inner cab corner side that faces the outter cab corner since there was no way to accomplish this after the outter cab corner is installed. Sorry, no pictures of that work.

After checking my dimensions for the door opening, i have decided to rehang the door, before proceeding with any more outter cab corner welds, as i have no good dimensions to use due to bondo buildup on both door openings where the rocker met the cab corner/pillar. I also need to do some work on the rocker as it was not fabricated to fit very well at the pillar/cab corner. The door line will give me a better target to fit to. Dang doors are heavy. Gonna need help to hang it. 😮‍💨

Here's what I did to hang doors single-handed. Should work on your 1958 as well.

Thanks klh. I dont have a picker. I borrow one when needed. I think i will cut a 2x8 to span the above trusses and use come alongs. I considered buying a picker. I will need one when i pull the cab from the frame.

Taking baby steps as the junction of rocker, rear piller and cab corner is critical. Tomorrow i hope to fit the rocker and move the door from the barn to the garage. I measured the two doors and found the width at the bottom to be almost 3/16” different. Lotsa hack work done on Stella in years past. I hope that resolves with all new panels.

I decided to temporarily set the step/rocker in place and get the rough fit done. It took some cutting and grinding at the junction where the rocker meets the cab corner. Im happy with it at this point. Need to set the door to make any final adjustments before i finish welding the outer cab corner.

The step comes back out while i replace the front door pillar. I have all the patch panels. Another challenge for sure. I hope the passenger side goes a tad faster.

I noticed the new step/rocker patch panel does not have the rocker reinforcement bracket that is present on Stella’s original step. Can’t find it in the Factory Assembly Manual or online. I guess i will need to rescue and reuse them.

Well I’m glad i hung the door to check gaps. I had to remove the outer cab corner to adjust the pillar and inner cab corner. Today, I started installing the cab corner for the last time. 20 more plug welds and a few at the bottom where the inner and outer cab corner come together and its in.

The lesson learned is i should have checked gaps as i was disassembling. Unfortunately, i assumed if i put the patch in the exact same place all would be good. I had sketches with dimensions to confirm panels were set properly. Won’t make that mistake again.

You’re taking baby steps, but making good progress. It’s definitely a learning process but seems so far you have learned from your mistakes. I bet the other side goes much smoother and a bit quicker.

Don’t be surprised if your three year project goes to five or six. Mine was a three year and now I’m in year six and I still have two or so years to go. My biggest issue is time. Life keeps reminding me it’s only a hobby and my family is the priority. I do enjoy my time in the shop and it’s my therapy that rejuvenates me.

Keep at it and you’ll soon see the fruits of your labor!

PS: Now that you have a new compressor, trade that Dremmel in for a pneumatic die grinder with a cutoff wheel. Your dissecting will go much quicker!

Thanks phak! I do have a die grinder with various wheels. The dremmel does better for super tight areas . Especially with the diamond wheel. The tiny dremmel flapper sanding wheel has been a blessing at times.

I thought retirement would offer more me time. But like you said, other priorities get in the way. Especially health. When i do get some time, i usually go at it for 3 or 4 hours. Its great for mental health.

I appreciate all the support here.

Those cab corners are looking good. Wish I had the skill to do this type of body work. Great progress.

You do! I was determined, took a welding class at the local junior college and practiced on scrap. Bought a used mig welder setup, compressorand a few air tools and i was off to the races. I probably watched 100 hours of video on you tube. Especially Bad Chad who aint bad at all.

I’m an amateur, other than my determination. And pickiness. I’m documenting my adveture here so others can use it for encouragement and lessons learned.

This site will help you do anything on these old beasts.

K

I took some time today to continue with final welds on Stella’s outter cab corner. I’m at the no fun part as there is a run of plug welds along the bottom edge. Welding upside down is not fun!

Just a quick update. Spent about 3 hours today finishing all the final welds on Stella’s drivers side rear cab corner
(inner and outer) and latch pillar. Happy to be moving on to the drivers side hinge pillar (inner and outer) and fender bracket. Progress has been slow, but I’m pleased with the outcome. 😁

Door is off, and I have marked most of the spot welds for drilling. I did order some new tools to make removal a bit smoother than the previous effort. My plan is to cut the pillar just above the lower hinge. I need to cut high enough to be above the floor so the hinge pocket panel can be removed and replaced. I will be using the entire patch panel for the lower cowl. Including the lower fender bracket, there are four pieces to remove and replace. Expect lotsa pictures and the painful detail associated with my posts.

Worked about 3 hours today starting to dismantle the drivers side hinge pillar. Once i removed the 1980’s vintage patch that was welded in from below, disassembly went smoothly. Pillar is rough cut and out, fender bracket about fell off. I was worried about removing the hinge pocket panel as there were supposed to be about 5 spot welds to the floor pan, none of which were present 🤷😗. One more spot weld to remove and it will fall out. I plan to finish lower cowl demo next time. I also plan to do an inspection of the cowl interior before closing it up to see if more must be removed.

I went back out last night cus i wanted the hinge pocket out. It just kept bugging me. I could not find any welds holding it in. The bottom end was rotted out, but there should have been 4 or 5 at the top attaching it to the floor pan. Nothing there, never was. I tugged on it a bit and it fell out onto the floor. You can see in the pic there are no spot welds across the top. I found this humorous since im the guy taking it out.

The project scope just grew. Just ordered a new cowl for the drivers side. I was not happy with my internal wire cam inspection, nor the rust on top at the fender attachment, nor the fact that none of the spot welds on the lower left side are holding to the material below. I scraped about 6” of undercoat off the seam and none of the 3 welds i looked at are holding.

She gone!

Its 90 degrees here today, but i spent 30 minutes rough cutting the ventlation cowling out to gain access inside. Glad i did as there was no other way i know of to deal with 67 years of surface rust. It was also packed with leaves I never would have seen without removal. I plan to scotchbrite the surface rust, treat it with phosphoric acid and seal it with epoxy and then install the new cowling.

First i need to remove all the spot welds.

Kevin - Appreciate the level of detail you go into to tell us how things are progressing. Pictures speak volumes. Hope things progress easier as you go.

Thanks gdads. Removed the rest of the spot welds except those across the top as i had no luck finding them. I ended up cutting the flange of the cowl and will butt weld the new cowl panel across the top. Started scotchbrite and wire wheel cleanup. Phosphoric acid is next. I’m hoping to get my hands on some Mastercoat silver to paint the plenum since I’m unsure i can clean the acid out well enough to use epoxy. Too many nooks and crannies.

While i wait for mastercoat, I’ll pull the damper operator cable and lubricate it. It’s difficult to operate the damper.