Crew Cab Stepside modfy and restore

[tRustyK5]

Instead of a full out build thread I figure I'll do this in parts as I go. I have an '87 Crew Cab 2WD right now that has an aftermarket utility shortbed on it. Around these parts it's known as a "loggers box"...which fits quite well as the truck was originally purchased by a large logging company.

Pretty ugly IMO...

I had this utility trailer kickin around. '58 GMC stepside longbox, pretty rough in places, some rust issues, but generally solid. I didn't get any specific before pics. This was the "good side".

So, I originally planned on shortening up a fleetside box...but I got to looking at this old stepside and thought I would do something either really cool looking, or really retarded looking. I'm putting a shortened version of the '58 stepside box on my crewcab in place of the utility box.

First step was to fully dis-assemble the stepside. No pics of that either. I then spent countless hours massaging the fenders back to straight, repaired some small rust issues, used the minimum amount of filler necessary and got them primed up and ready.

For a body work n00b like me compound curves are prolly not the easiest thing to start with. I have about 70-80 hours in that pair of fenders (rough guess...i'm slow I guess)

Next was to repair the first boxside, shorten it up etc. I drilled out all the spot welds holding the posts to the side, then spent a few tedious and frustrating hours with a hammer and dolly getting them close to normal shape. The rear post I had to fabricate a lot of, but it was nearly crushed...

Today I'm shortening up the actual step at the front of the box. To ensure good fitment I felt it was necessary to bolt the fender to the bedside and fit up the step parts for tacking to the assembly.

long shot of assembly:

Closer shot of front section of new step:

Both half's clamped/bolted in place.

Closer shot

This is the size of the original step...

Side shot

This is what the bedside looked like before I started with it.

So that's where I'm at so far. i'll update this as I progress. I still have the second bedside to shorten/repair/smooth and prime. Plus the second step, then a few ribs and supports need a bit of work and I can paint/assemble.

I'm still trying to decide the best way to paint it. In pieces, or pre-paint areas that will be covered up later, assemble and paint as a complete unit...or??

We'll see i guess. I don't have a terribly large indoor area to work with, so that may decide it for me.

Rene

 

[tRustyK5]

Some things I did think to look at and check before starting this.

First was the shape of the '58 fender opening.

I compared it to the front fender and the opening is very close in size, and more importantly I'll be having to alter the front fenders for a bit of tire clearance anyways...so i will match the fender opening to the same rear angle as the '58 rears.

Second and more important to me was the height of the body line. On a 73-91 fleetside box that height at the front of the box to the body line is 9", at the rear of the box it's 9 3/8". Hard to notice that the body line isn't paralell to the top of the box...

The '58 stepside box the body line on the fender is 9 1/4" down from the top of the box side.

I'll be able to match the fender's body line with the body line on the cab perfectly. The only thing somewhat odd looking (maybe?) will be the different era fenders. I plan on using the older front clip on this truck too...which I think will help sell the overall look a bit better.

Really, if I find it just looks stupid I can do one of two things. One is swap to a set of 73-87 stepper fenders (shouldn't be hard to do...but i don't care for them much) or I can suck it up and shorten the fleetside box I also have.

Anyways..back to the shop.

Rene

 

[AJMBLAZER]

Ummm...lotsa work for your wheeling rig's body.


Nice work though. I just don't have the patience for this sort of thing.

 

[tRustyK5]

This isn't gonna be a hardcore wheeler. Trails, exploring, fishing spots, camping etc etc. I doubt I'll run any bigger than 37" radials. I would likely take it to Moab, but I'd be playing with the sheetmetal gang for sure. I want this truck straight and somewhat pretty. (not like the K5...lol)

Rene

 

[AJMBLAZER]

Yeah, I remember you saying you kinda overbuilt it. Know the feeling.

 

[tRustyK5]

Got the step put together...

Down to bare metal and reclamped:

Tacked up...you can see the height misalignment where it bolts to the underside of the bedside. I dealt with this later, I wanted the outer edge and all the ribs to line up and be solid before I did anything with that area.

Welded:

Ground and ready for a coat of primer:

Right now it's sitting in primer, as is the support braket that bolts to it. Either later tonight or tomorrow I'll throw a bit of mud on it. It's actually pretty damn good for just being welded and ground, and although it's just a step I want it to look a bit more finished than it does now. It also has some pitting that needs to go away.

Rene

 

[Greg72]

Subscribed, Inscribed, Described.....

Gotta keep an eye on what yer doin' Always fun to see masterful welds and creative thinking.

 

[Chaddy]

Thats looks awesome Rene! Keep it up, and I will see you in Moab for BB10!

 

[bronc3buster842001]

Looking good.

 

[dbabicky]

Looking good. I think that'll be sharp as heck when you git'r done.

 

[tRustyK5]

Short step done...

Gonna disassemble and store this side and get started on the second boxside in the next few days.

Rene

 

[twoslo4five0]

what welder you using in the background?miller?

 

[tRustyK5]

Miller 135. I got it just before they brought out the 140. 220 wasn't an option when i got it...

One nice thing with sheet metal as old as that stepside is that it is notably thicker than the newer stuff I'm used to.

Rene

 

[rob h]

Looking good, that older bed should look good. The welds look great also...

 

[82355]

I like the looks of that box, much better than the "correct" stepside box. It will be interesting to see how this turns out.

Martin

 

[thatK30guy]

I love the lines on the '55 to '59 trucks. No chance in trying to get you to use a different bed for the CC? I'd like to see you fix up a '55 - '59 truck to go with your bed.

 

[tRustyK5]

One day I will build a Task Force era Pick-up properly...I love em too. When I bought this as a utility trailer the guy had three to choose from. The other two were not only in better shape, but better built...but they were all home built. I chose the '58 GMC because it was a '58 GMC. I figure using it on my Crew Cab is saving it already.

The ugly utility box from the Crew Cab is gonna be mounted on the utility trailer frame with the 2WD 14 bolt from the CC under it all.

Gonna whore one more pic. I mocked it up for wheel center with an old 36" TSL i have had for a while. It's near enough to the 37's I want to run, so i ballparked the height while I was at it. After some careful marking on the floor, and dubious use of my bubble stick I've determined my rear diff needs to be 30 3/4" rear of the back of the cab. This gives me 1" between box and cab and shortens up my wheelbase to 139 1/4". Should be great for climbs, steps etc etc. Overall length will be the same as a regular cab longbox.

Rene

 

[blazin_blazer]

subscribed...i want to see how this turns out. the way the rear of the older step side fender slants back, that would look good w/a cut front fender. or maybe find another set of those step side fenders and graft the rear of the wheel well lip onto a 2nd gen front fender...that would give clearance toward the firewall and look finished at the same time!
definitely interested in this!

 

[tRustyK5]

I'll snap a pic of the '76 front fenders I have. The lip area is so similar that it's spooky. My plan is to section out some metal at the rear of the fender as per standard trimming protocol ( ) but keep the lip. It should match up well enough...

Rene

 

[blazin_blazer]

i can tell from the pics of the rear fender, it looks like it will come together nicely. are you going to try and retain the inner fenders?