Metalwork has to be one of the most time-consuming parts of building a custom truck. Welding up the holes from the trim, door handles, and various other factory annoyances takes patience and someone behind the welder with the skill to execute the mods perfectly. This obsession with bodywork perfection continues from the time welding begins to the day the truck is eventually rolled into the booth for primer.
Last month, we introduced you to Project Red Rocker, an '85 Chevy C10 pickup that Hill's Hot Rods in Lubbock, Texas, will transform into a shaved, 'bagged, and rim-stuffing custom with a spicy red topcoat and intense licks of fire burning down the sides. We highlighted the project last month, discussing the classic Corvette-themed dash and interior framework, and ran down a quick list of the truck's targeted modifications, including the companies who will be involved with the project. In addition to painting a mental picture of the truck's desired finished state, we also whet your appetites with a rendering by Ed White of Fast Eddy's Hot Rod Art, depicting the slammed and fiery appearance our C10 will eventually take on. After tearing the truck apart in Part 1 of Project Red Rocker and beginning on some mild metalwork, this month we aimed to shave the entire truck, weld on the custom Grant Kustoms roll pan, and get all the metal into primer.
Over at HHR, sparks were flying and dust was in the air as the HHR crew proceeded to carry out the long list of metal alterations to smooth and sanitize the body. Follow along as we witness some 20-year-old sheetmetal reach a whole new level of cool.
On any show truck, the details...
On any show truck, the details are what truly make the difference. In the doorjambs of Red Rocker, the factory spot-welds were smoothed before the rest of the truck was shaved clean.
Hill's Hot Rods' Nathan Hunter...
Hill's Hot Rods' Nathan Hunter ground off the paint surrounding the factory mirror holes to prepare that area for welding.
Masking tape was placed over...
Masking tape was placed over the main door handle opening and the perimeter of the hole was traced out, so a pattern could be created to cut out the metal needed to weld it closed. The same procedure was done with the key lock hole.
Here the tape templates were...
Here the tape templates were stuck onto metal so filler panels could be cut out and fit in place on the doors for final welding.
Nathan welded up the factory...
Nathan welded up the factory mirror mounting holes. Once the truck is painted and finished, a set of billet aluminum street rod-style mirrors will fill in for the oversize factory mirrors.
The door handle and key lock...
The door handle and key lock openings on the door were welded up.
Here is one of the doors after...
Here is one of the doors after all the metal alterations were made and the welds were knocked down with the grinder. A moderate amount of filler and finishing puddy was used to fill any gaps before any sanding or primer is applied.
Both doors waited through...
Both doors waited through long sessions of sanding after filler and finishing puddy were applied to the areas in need of some evening out.
Nathan performed wet-block...
Nathan performed wet-block sanding duty on the passenger door after the primer was misted onto the body-worked areas. The purpose of this was to make the metal consistently flat and smooth using the flat surface of the block as a gauge.