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View Supercharged03's profile Entries: 108
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02-06-2012 09:21 PM S10 fabrication (cont'd)
I reworked the fit of the Malibu driver's side rear window frame to the S10 passenger side door. This was the third time I've adjusted this, so the inside panel of the S10 door is fairly chewed up. I spent 3 weeks getting this door right.


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  [Entry #13]

01-31-2012 08:58 PM S10 fabrication (cont'd)
Finally removed the S10 front and rear windshield to see how the 55-56 Chevy windshield would fit. I removed the S10 roof and A pillars, too. The curve at the base of the 55-56 windshield is close to that of the S10, but it's off enough that a new base will have to be constructed with the rest of the windshield frame. Cleaning up the S10 windshield opening showed me that my guesstimate of the depth of the 55-56 windshield was off by 3 inches, requiring some rework on the Malibu window frame in the S10 door. I also will need to adjust the angle of the window track in the door to match the side angle of the 55-56 windshield.

Oh well, it's just metal.


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  [Entry #12]

01-26-2012 08:40 PM S10 fabrication (cont'd)
I discovered by accident that the width of the S10 cab at the base of the windshield is the same as the width of the 55-56 Chevy sedan windshield. A body shop that my son works with had a customer's 56 Chevy that was having all of its glass replaced. They gave me the old windshield, completely chip-free, for free. I have wanted to chop the top because the slant of the S10 windshield contrasts so sharply with the more vertical windshields of the 30s and 40s, so getting the 56 Chevy windshield forced me to search for windows that would work with the S10 doors and the wrap-around windshield. After spending several days searching through wrecking yards and used car lots, I settled on a few car models that would fit, including the 1997-2003 Chevrolet Malibu. My latest Craigslist.com find was two rear doors and the entire roof of a 2001 Chevrolet Malibu for $160. Here's the first S10 door modified to house the Malibu window frame, including the power window motor.

I am 7 months in to this build now, having started the S10 disassembly in June 2011.


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  [Entry #11]

01-26-2012 08:16 PM S10 fabrication (cont'd)
Another Craigslist.com find was a pair of 40 Chevrolet headlight buckets. I like these because they mimic the Pierce-Arrow characteristic of having the headlights molded into the fenders. I had to fill in the lower portion of each bucket to get them to match the asymmetrical curve of the Ford front fenders.

No, I am not making a Grave Digger replica.


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  [Entry #10]

01-26-2012 08:07 PM S10 fabrication (cont'd)
The rear fenders are hung on the sides so that the top of each Ford fender parallels the top of each S10 fender. The angle of the slant on the rear Ford fender is duplicated, as best I can judge, on the front Ford fenders. While the rear Ford fenders will have all of the rusted-out areas removing when they are trimmed to fit, the front fenders have required a good deal of patching. Luckily, I have been able to reserve enough of the compound curves in the Ford fenders to allow me to bend the patches by hand and with a hammer and dolly.


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  [Entry #9]

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