The Final Build

Follow the final build of the 55 Chevy Pickup.

The post is in date order, so start from the bottom of the post.

I am not going to make any prediction this year about the time line to finish the project, for anyone who has read the pre build the original time line is a distant memory.

Enjoy the final chapter of the restoration. 

P.S. Go to the Photo Gallery to check out all the build photos

16 November 2016

Took the Chevy for it's roadworthy today, passed with no defects, all good.

Started the project June 2013 and on the road full SA Registration today.

Picked up the custom plates and fitted them, "55 CHEVY"

3 years and 5 months to rebuild. Still a couple of cosmetic items to complete and finish running in and adjusting a couple of things.

Looking forward to taking the truck on some of the local runs and to the Nationals at Easter in Bendigo Victoria.

Big Thanks to all the helpers and suppliers, big brother for having a Chevy on his hoist for 3 years, Sean and Ross for putting up with all my questions and there help.

Chris (Mobile Automotive) for the rewiring and emergency support when things weren't working.

30 October 2016

Took the Chevy under permit to Blackwood Cars and Coffee morning on the way to complete the paperwork with our clubs Tech officer David.

Another tick in the box for Regency and getting rego for the Chevy.

Next weekend final inspection at home and a clean after the run and will be good to go to Regency for the Roadworthy Inspection.

14 October 2016

Met up with Stuart form Tonkin Engineering today, for the final inspection.

Stuart took the Chevy for a drive and decided that it did not need a lane change test.

So good to go to the roadworthy inspection at Regency.

On the trip back called into the inspection center to do the Identification check.

Completed the paperwork and got the ID check done after some discussion about crate motors and how they get numbered? And another discussion about the original compliance plate and a replica plate.

Original plate in place and the replica plate removed all was good. 

Booked in the roadworthy for 14 November 2016.

9 October 2016

Still waiting on the engineer, there is some indecision if I should have a lane change test (moose test) or just  a public road test?

Once I get this sorted I will be able to get a vehicle ID check and go to Regency for the final inspection and registration.

I have the truck booked for the first display at the Adelaide Motor Sport Festival 19 & 20 November 2016.

August 2016

Lessons Learnt

I would spend more time understanding the tracking before the build to make it easier at the end, even though we replace the old suspension with the same specification (hub to hub) measurement in the front, the original Chevy has 150 mm difference from front to back, we are only aloud 75mm form front to back.

Hard or flexible fuel lines, no brainer here, go for the flexible lines. I have had to replace the hard lines with the flexible lines as the vibration kept on making the joints weep, no problems with the flexible hose and it is much easier to work with.

I would do all the brake lines before painting the chassis next time, I have made some changes from the original lay out, so have a couple of extra nut serts in the chassis.

Recommend nut serts for everything, they are great, rather than using self tapping screws, I have gone for the round alan key head machine screws, the original kit was not too expensive.

To do List to get to Regency for Rego:

Need to get the Dash to read the Auto in Park position.

Sign off the the inspection mods form the first inspection

Needs an identification check, local police will do that.

Lane change Test and sign off by the engineer.

I have done the 500km so I will drain the run in oil and fill with running oil.

I will take it down to get it on the Dyno just to set it up, I plan to take it back say after 2000km and see if the engine meets the Chevy spec 350hp, this is just a first set up to finish the run in, so far it is just out of the box, we have only checked the timing.

Book in the Final Inspection for Registration

24 June 2016

Back down to Exhaust Tech the two 6 inch resonators are in and ready to install.

At least no rain today, but cold, 4 deg going through Mt Barker.

Pretty happy with the look and the noise level is a much more comfortable level.

Need to get the DB meter out to check but should be OK.

18 June 2016

All the nuts and washers have been done.

The drivers door mechanism is playing up, it's the original, so ordered an new one. I replaced the passenger (US drivers door) side and should have done both, I thought the US passenger side might be OK but forgot the old girl is 60 years old.

10 June 2016

Drove the Chevy under permit to Exhaust Tech to get the exhaust mods done.

They could not get the resonator Mark wanted so have to come back again Friday week.

Copped the rain and fog down through the Hills but the Chevy was all good, no leeks or electrical problems and the wipers work.

The headlights first test on the way home all good with high beam giving great vision through the country roads back home.

Gave the Chevy a good clean using McGuire's water less clean, worked pretty good, the tip is to use plenty of washable microfiber cloths the Web Site tells you.

4 June 2016

Hot Rod Club Technical Advisory Committee TAC Pre registration Inspection.

The pre rego inspection was carried out today by Richard Watkins and David Johncock.

Very thorougher inspection for 2 1/2 hours, another short to do list.

Exhaust needs a small modification, clashing with the bump stop, (I did not have the bump stops on when we did the exhaust) did not quite make the noise limit of 96bd, came in at 103db, so back to the see the guys at Exhaust Tech.

A few spring washers missing on the side step and two bolts on the back suspension not showing two threads.

A small mod to the hand brake mount to straighten the cable pull.

Two nyloc nuts on the fuel tank straps and a stainless trap around the fuel filter.

The big one is the tracking does not meet the specifications even though it is the same as the original specs.

I will have to get an engineering report and do a lane change test.

Pretty happy with that. 

22 May 2016

The Chevy hit the road for the first drive yesterday. I took it to Bleadsdale under permit to their registered weigh bridge. Weighed in at 1500kg, Thanks Sean. The 350 Chev motor should handle that all right.

Set up the speed on the Dikota dash on the way, just a couple of items to complete the dash setup.

The drive went well, handle great, (the road to Langhorn Creek has a lot of bumps and turns). 

After the drive check around, no leeks, the back right Wheel and the diff running a bit warmer than expected so will follow up on those.

New gears in the diff may be just settling in? Oil is SAE90, diff is limited slip

Brakes just check the shoe adjustment.

The noise level in the Cab was lower than I expected,the insulation doing its job.

A couple of things mostly cosmetic and I am good to go to the Hot Rod Club Technical inspection. An Identity check and the Registration inspection and the Chevy should be on the road.

I have my number plate for the Chevy,  Custom Plate "55 Chevy", paid the anual fee today.

Tried to get a yellow on blue to replica the California original plate but South Australia does not do yellow on blue so went for the blue on yellow.

March 2016

Dropped the truck at Daves, 3 days and he has it ready to pick up, looking great. Black carpet, b lack boots for the gear stick and handbrake.

Headliner in, pale off white, created some discussion on colour and still creating discussion. Every ones an expert after the fact, the truth still not sure but may end up going to black?? only money.

The new leather seats is in look great. Bought the side mirrors from the US and tryed to fit them and oh yes, rookie error, they don't bend to the right angle for a right hand drive! Small bend in the drivers side has the mirror working but will need to make a matching one for the passenger side. 

February 2016.

SRR Hot Rod Show first weekend in Feb, big success all went great. Southern Rod Runners

Bought all the sound proofing from Car Builders, fantastic gear, 2mm heat and noise and the 6mm sound deadened.

I placed 3 sheets on the inside of the cab roof, any one who has tapped a roof of a pick up, it sounds pretty tinny. The sheets have made the cab roof sound great, no tinny noise.

All set to go to Dave  Auto upholstery in Mt Barker.

January 2016

New lock arrives from MLC in the US.

Just enough space to get the lock out with out pulling all the insides of the door out.

Trying to finish all the small jobs left on the to do list, from the Rod Club Tech Officer.

Fitted the safety Belts, small problem the frame required a small mod to take the center belts.

December 2015

More time finishing electrics, front sway bar and brakes.

Fit all panels and bumper bar, passenger door not locking, old lock needs replacing.

 

26 April 2016

Not sure where the last 4 months has gone. New job, Christmas, Wife's major Birthday. The Southern Rod Runners first 3 day Hot rod show in February.

I will update the restoration.

22 November 2015

Still in the west working, looking forward to getting home to work on the truck next weekend.

To do:

Finish setting up the brakes and bleeding them.

Bolt up and align front panels.

Put the wooden tray back in, (had to remove to re run the brake lines).

Finish interior fit out.

Book in the final inspection.

 

Chris has sent through photos of this weeks electrical work, getting close to completion.

All rear light working, reverse lights in the tray All wiring in the engine bay hidden

  

Under dash LED foot well lighting Wring all neat and tidy on the engine

  

Changed over the ball joint as there was play all bolts with 2 thread clearance

in the new joint straight from the kit

4 November 2015

Rerun the brake lines away from the exhaust.

Both doors on just need some adjustment.

Bought a new set of rims to meet the tracking requirements.

New safety sign for the work shop: Pays to work safe.

2 November 2015

Had the pre-inspection today from David the Southern Rod Runners Tech Officer.

My to do list is bit longer but nothing that can't be fixed.

Need to fix the tracking, front to back center of tyre can not be any more than 75mm, 

Some nuts don't clear the bolt by 2 threads

Need to rerun the back brake lines to give greater clearance from the exhaust

Need a steering stop to stop the wheels touching the chassis

Need a new rear window, no compliance stamp, flat glass so can get it made in Adelaide, curved cab glass has safety stamp,

The rest just house keeping bits and pieces

10 October 2015

Had a good week trying to finish of the truck ready for Tec inspection from ASRF. Hopefully book them in for November.

The tray and back of the truck is complete, wooden tray, lights and rear axle.

Ordered the last bits and pieces, final trim and small components.

Trial fitted the seat to see if it clears the speaker boxes behind the seat, all good. I will have to remove the seat to get the carpet installed.

Front panels have been fitted, just the bonnet to fit.

I removed the Water pump and spindles for finial paint, they are cast steel.

Installed the piping trim around the guards, looking good.

Doors will be ready to fit next swing, Ross has been busy fitting the new felts and glass. 

Brakes

We have adjusted the hand brake and rear drums all good.

Not so good with the foot brake, Tried to bleed the brakes and still have no peddle, 

After consultation with the mechanical advisers, have a couple of options to check, but have to go back to work.

I will try them next swing.

May be a stuck piston in the master cylinder?

Maybe with the master cylinder under the cab I need to raise the front of the cab above the bleed point in the rear brakes?

Maybe the travel of the piston is not long enough?

28 September 2015

Had issues with trying to keep pressure with the original radiator. Bit the bullet and have removed it and having a new core installed, keeping the top and bottom tanks.

Looked at the new Aly radiators but don't think they would suit the look I am after.

Run the motor for 10 minutes to finish running in the CAM, Need to do an oil change and refill with the thin oil for 500km

 

15 August 2015

After two years Sean and I started up the new ZZ4 350 today.

Sounds great with the 2.5 inch stainless steel exhaust.

We had to tighten a couple of joints in the fuel line, adjust the fuel pressure gauge, one joint in the power steering otherwise no leeks. (except for the Radiator)

Primed the motor with oil using the priming tool on the drill.

Set all the plugs leads to the correct position and a little adjustment to the dizzy.

There was a fair bit of smoke from the mandrel oil in the exhaust which cleared after a bout 5 minutes.

We could only run the motor at 2000 rpm to run in the cam.

13 & 14 August 2015

Had a couple of big days, Chris (Mobile Automotive) has been finishing off the wiring loom, enough for me to be able to start the motor on Saturday.

Chris has the power on and light up the new Dakota Gauges

I have been filling the fluids ready for the big start up.

Filled up the radiator and pressure tested to 14 psi and poped a small leak at the top of the radiator. Will still be able to start but will have to remove and solder up the hole patch up the paint work.

It is the original radiator which has been restored and tested but has sat for 12 months?? Hope it will be OK.

11 August 2015

Loaded up the Chevy into the race trailer and towed it down to Adelaide to get the new exhaust installed.

A custom 2.5 inch stainless steel with a mid mounted crossover muffler.

             

2 August 2015

Still working away so trying to organise a busy week when I get home.

Booked in the Exhaust installation.

Ross to fit up the doors and windows, may be the final panels.

Chris will have another day on the electrics

Booked everyone for Saturday 15 August, fill all the fluids and turn the motor over for the first time. The Big Day!

To do list:

Install throttle mount.

Fill fluids

Final check before the start up.

30 July 2015

The new Front Wind Screen has arrived in Sydney at last, it was ordered last year, but it took a while to get the right screen, being a 55 series 1, not quite as prolific as the 54 or 55 series 2. It appears to be slightly different to both the other trucks. I could have purchased it on line from the US for $129 but they wanted $600 freight, so settled for sea freight. Timing has worked out pretty well though and has not held up the project. Had the old one as back up if needed.

27 July 2015

Chris continues on with the wiring, Wired the engine equipment and started under the dash.

22 July 2015

Chris has done the first day on the Chevy laying out the loom and working out where all the bits go.

Mounted the Fuse Box

8 July 2015

Fitted up as much electrical as I can and am out of my depth here. Ross has recommended Chris Stanton, Mobile Automotive to do the wiring and AC work. We had a look over the Chevy and he is all set to start work.

He will do one day a week for the next four weeks and see how we are going from there.

Fitted up the AC controls, Ross made an aluminium panel that fits behind the ashtray, I removed the ash tray and reinstalled the ashtray dash panel with a hing and magnet closer. Polished up the panel and refitted the AC controls, looks sweet. I had the work light behind when I took the photo, might have to hook up a small blue LED when the panel is opened. I like the back light.

27 June 2015

Have been looking for radiator hose solution, all outlets have a different diameter. Found a Stainless Steel solution on EBay, comes with Stainless ribbed tube and SS end covers and multiple rubber ID and OD inserts.

The stainless suites the over all finish I am looking for, matches the big stainless air cleaner on the motor.

Ross has had a crack at the front grill chrome to tap out the dints, come up pretty well so will fit it and see what it looks like. The nose piece has the biggest dint so I can buy that piece new if needed. Worst case I can get a new grill assemble and dull it off to match the rest of the truck.

13 June 2015

Checked all the brake lines and fuel lines, made the changes to the brake lines where they were hooked up incorrectly.

Still need to clamp the brake lines to the chassis, fill with fluid and bleed.

17 May 2015

Had the power steering hoses made up and fitted them this week.

Fitted the spark plug cables and mounts. Iner passenger side engine bay is fitted, I will leave the driver side until one of the last items for access to the motor.

13 May 2015

Fitted up all the dash switches, electricals and fitted the fuse panel into the air vent in the right hand panel between the door frame and the fire wall.

24 May 2015

Fitted the Flaming River Steering column and Linkages to the new Power rack. SS uni joints and a collapsible shaft from the Rack to the bottom of the column.

Fitted the new Dakota Digital Instruments, looking cool. Started fitting all the electrical equipment and dash switches ready to start running the loom.

23 May 2015

Returned the Cab back to the shed and mounted it to the chassis.

Ross has also finished painting the Steely rims, sent them down to Dom at North Terrace Tyres and fitted up the BF Goodrich Radial TA P275/60 R15 107S M+S. Created some discussion on having all four the same width, not a hot rod look apparently, but in my defense the Chevy has big front guards and a smaller tyre would get lost under those big guards. Let me know your thoughts? You can post at the bottom of the section.

12 May 2013

Ross has spent the last 3 weeks preparing the cab and the final panels for painting. All inside panels will be Chevy Green and the outside rubbed back with 900 paper and Coated with a Commercial Grade Protec Satin Clear. 

Just have the seat slides to clean and paint and work out what to do with the front Grill, the chrome has a couple of dints in it. A new grill may look out of place given the paint job.

2 August 2015 Finally found time to update the build, work has been busy but still have had time to progress the build but not update the build, will catch up the last three months. I will update from memory and photos I have taken.

25 April 2015

Returned the Chassis to the work shop, should have the cab finish painted in two weeks

Jobs to do, Finish motor accesories, radiator and hoses, fuel pressure gauge

Run the wiring loom

Power Steering hoses

24 April 2015

Purchased the new tires today

18 April 2015

Ross has worked through the Cab and chassis and fixed and fitted out the last of the modifications

Trial fitted the column and ordered the column drop

Trial fitted the A/C unit, made a custom bracket

Trial Fitted the Retro Radio into the dash

Welded out the unwanted holes in the dash

Modified the engine bay panels to avoid the clash with the new suspension

Set the Cab and Panel heights with spacers

Fixed the rubbing of the brake disc on the suspension arm I had fitted back to front.

Identified a problem with the brake lines and master cylinder front and back back to front.

Front rims have been cut and reversed to clear the brake calipers, all good now.

4 April 2015

Transported the chassis and cab to the Paint Shop for final fitting and painting

14 March 2015

Installed the Fuel lines with the Aroflow Fuel logger, Holly electric fuel pump and the two Holly fuel filters.

Installed a 2 inch space block between the carbi and the heads to raise the fuel logger from the rocker covers and achieve better performance.

 

 

9 March 2015

Had a big week end in the workshop, we have the truck on four wheels Yeh!!! , motor and gearbox in for the last time, fuel tank mounted, the height and the angle all looks good, just need to rubber line the steel straps. Just need to insert the sender unit in the tank and screw on the breather and filler. the filler will be inset into the wooden tray floor drivers side.

Another update on the suspension, the Hiedits front end has ended up with only a couple of mil clearance from the lower arm to the "hub" on the right and is just touching on the left.

Look like we will need a 3 mm spacer behind the rotor so it will clear the lower arm on the left, we can not find any mistakes as yet but will keep checking on the left hand front suspension.

The front widescreen is still in transit from the US.

 

2 March 2015

Dropped of the fuel tank straps for painting, it has taken a while to get the mounting solution but pretty happy with the out come, two steel straps have been bent around the tank with two bolts on the front and a 25mm square tube supporting the back of the tank on two mounts welded to the straps.

 

22 February 2015

Picked up the seat frame from Ross at the paint shop, he has done a great job matching the leather colour.

Put the bench seat back together and of course had the first sit on the floor in the spare bedroom. The wife has made the comment that it is more expensive than our lounge suit, so I can see a new lounge suit on the shopping list (after the Chevy is finished).

 

15 February 2015

Had an OH Sh!!t moment today when I tried to place the new rims over the brake callipers, looks like they will not fit with the way we have welded the off set and the orientation of the rim.

Rooky mistake did the off set with the hubs on and no brake callipers. Looks like if we rotate the rims and change the off set on the front they will fit, more time more money.

 

 

7 February 2015

Started the brakes, running the brake lines to the back brakes, I am using 3/16 Stainless lines which have bent pretty well, you only get on shot as the stainless hardens after the bending, almost impossible to unbend the tube.

Had to make some custom brackets for the brake lines and the hand brake. The rear is done and looking pretty good. Had a tug of war with the drum brake springs to get them into place. All new springs and cylinders with relined shies.

A couple of hints from Murray (a work mate) on the sequence to install the drum components was a big help, as always the second one went in much quicker than the first one.

Just the flexi hoses to get made and the rear brakes are done. Actually the rear end is done

Reco transmission Turbo 350 with a fresh coat of enamel ready to install

2 January 2015

Summary to Date:

Most of the big ticket items  have been ordered or purchased and are sitting in the work shop or the spare bed room.

All the panels have been painted, just the cab to go and then some small items.

Tray is complete and ready to be bolted back on the chassis.

The truck has been pre built to check all the modifications fit together.

So, ready for the final build!

 

To Do List:

Finish the cab repairs, dash, speaker positions and mounts for safety belts. need to work out all the switches and blank off the ones we don't need.

Drop of the rims at Adelaide Rims so they can be welded at the correct off set 25mm from the front lip.

Send the cab off to paint.

New Front Wind Screen is on Order, coming from the US so will land about Feb 15.

Dismantle the seat and send the frame off to paint.

Fuel Lines, Brake Lines and wiring loom

 

31 December 2014

Ordered all the bits for the fuel lines today. I have gone with the Black anodise hard fuel line and fittings from Aeroflow.

Brake lines will be Stainless Steel. I am a member of the Southern Rod Runners and they have the tools for flaring and bending the hard line.

 

30 December 2014

Picked up the chassis and rear suspension components from the paint shop and set up for the final  build.

Dropped of the engine bay panels for slight modification to clear the new front suspension and add a cover for the accelerator mechanism.