1950 Chevy Suburban Buildup - Body Side Panels

Chopped+Sectioned=Hammered!
After slamming the suspension, it was time to resculpture our '50 Chevy Suburban project. In order to deliver the ultimate wow factor on project Sublime, it was decided to alter its profile with five major body mods: We chopped the roof and sectioned the body side panels, cowl, hood, and doors.

To physically hammer the fat 'n sassy 'Burban, it was very important to keep the body alterations proportional. These fat-fendered '48-'54 body style trucks and SUV's have tall doors and side body panels. Chopping only the top three inches through the windows and windshield would exaggerate the height of doors and body panels. To keep the 'Burban's profile proportional, the doors, body panels, cowl, and hood would be sectioned an even three inches. The 'Burban's two-piece split windshield was removed in order to graft a '52 Chevy coupe one-piece radiused windshield, along with A-pillars, and top of the cowl onto the 'Burban's cowl.

To accomplish these critical body transformations we called on Dan Dowdy and Dale Taylor at Street Rods by Dowdy in Dolan Springs, Arizona. The customizing experience between these two metal masters is damn near a hundred years. Dan and Dale were definitely the right sheetmetal sculptors for the job. A total of 6 inches of metal was removed from the old 'Burban's body to totally change its profile.

Follow along as we will show you how these mind-blowing body changes were created by Dan and Dale.

Sublime was delivered to Street Rods by Dowdy, in Dolan Springs, Airzona, where it was about to undergo major body surgery. The main concern was to keep the body proportional. To do so, the roof would be chopped three inches, along with the body side panels, doors, cowl, and hood.
Sublime was delivered to Street Rods by Dowdy, in Dolan Springs, Airzona, where it was abo
Prior to chopping the roof, the window glass and doors were removed.
Before I knew it, Dale had armed himself with a Sawzall and made precise cuts and removed the roof.
Before I knew it, Dale had armed himself with a Sawzall and made precise cuts and removed

To maintain Sublime's fat and sassy profile proportionally, the body side panels were sectioned three inches through their centers.
To maintain Sublime's fat and sassy profile proportionally, the body side panels were sect
Dale carefully realigned the sectioned top portion of the side panels before tack welding them into place. After each tack-weld was applied, it was hammer-welded using a dolly and body hammer. This counteracts shrinkage of the metal and creates a maximum bond of the two panels.
Dale carefully realigned the sectioned top portion of the side panels before tack welding
Hammered! With the roof laid back on top of the sectioned side panels, we see the dramatic difference of the roof line. Notice the portion of the A-pillar that will be removed to create the mail slot shaped windshield. If you look closely you can see they removed the C-pillar of the backside windows to make room for one-piece glass windows.
Hammered! With the roof laid back on top of the sectioned side panels, we see the dramatic

Dan manned the plasma cutter to cut through and remove the firewall and cowl section.
After removing a three-inch section from the firewall and cowl, Dan and Dale realigned it. The cowl was then tack-welded with each individual weld being hammer-welded.
After removing a three-inch section from the firewall and cowl, Dan and Dale realigned it.
Dale observed Dan using the Sawzall to make two precise cuts through the doors.

After cutting and removing the door section, Dan realigned the two pieces of the door.
The two door pieces were then tack-welded an inch apart.
Dan aligned a body palm dolly underneath the fresh weld, then used a body hammer to hammer the weld.
Dan aligned a body palm dolly underneath the fresh weld, then used a body hammer to hammer

After the passenger door was sectioned three inches and tack-welded back together, it was propped up next to the unsectioned and chopped driver-side door for comparison. Note that the passenger-side door window had not yet been chopped three inches.
After the passenger door was sectioned three inches and tack-welded back together, it was
A disc grinder was used to remove a section of the roof to allow the windshield to be grafted into the roof.
A disc grinder was used to remove a section of the roof to allow the windshield to be graf
To eliminate the '50 Suburban flat glass split windshield, a '52 Chevrolet coupe one-piece radiused windshield, along with A-pillars and cowl was aligned, and then tack-welded into the roof and cowl portion of the Suburban.
To eliminate the '50 Suburban flat glass split windshield, a '52 Chevrolet coupe one-piece

When the hood was sectioned three inches and pie-cut, the top portion of the hood moved forward one inch. An Eastwood shrinker was used to fabricate a one inch extension piece of metal that was tack-welded to the rear of the hood to make up the difference.
When the hood was sectioned three inches and pie-cut, the top portion of the hood moved fo
After making the appropriate alterations of the original Suburban hood, Dan realigned and mounted it.
After making the appropriate alterations of the original Suburban hood, Dan realigned and
To eliminate the ugly factory barn door exterior hinges, a set of Hagan door hinges were installed inboard to smooth the rear portion of Sublime. An acetylene torch was used to heat up the hinges to allow the rear barn doors to open past 90 degrees.
To eliminate the ugly factory barn door exterior hinges, a set of Hagan door hinges were i

The Hagan hinges made for a clean installation.
They say a picture is sometimes worth a thousand words, in this case chopped + sectioned = hammered! Sublime, stitched back together, looks like Frankenstein. The welds were knocked down with a grinder and were ready for some protective primer.
They say a picture is sometimes worth a thousand words, in this case chopped + sectioned =
Dan used a Sata-92 paint gun to lay down a couple coats of Uro-Fill sandable buff primer to protect Sublime's rearranged skin and scar tissue.
Dan used a Sata-92 paint gun to lay down a couple coats of Uro-Fill sandable buff primer t

After a couple of coats of Uro-Fill buff primer, Lexan temporary windows and windshield were cut out then painted black to simulate the finished effect.
After a couple of coats of Uro-Fill buff primer, Lexan temporary windows and windshield we

FROM THE DRIVER SEAT
When dreaming of building my custom '50 Chevy Suburban "Sublime", I had visions of cruising up and down Pacific Coast Highway in a chopped, sectioned, pancaked, and slammed custom ride. The body profile would be proportionally altered creating a metal sculptured masterpiece and Street Rods by Dowdy pulled it off!

Dream it, build it, drive it and show it.

YOUR QUESTIONS ANSWERED

Time Spent Working: 32 Hours
Degree Of Difficulty: Advanced

Tools Needed:
Sawzall, tape measure, straight edge, MIG welder, body hammer, body palm dolly, plasma cutter, Eastwood shrinker/stretcher, disc grinder, acetylene torch, Crescent wrench, assorted 3/8-inch drive standard sockets, 3/8-inch drive socket, assorted combination wrenches, disc sander, 3M Scotch-Brite pads, Urofill urethane buff primer 10-2234, activator 10-2233, Sata-92 spray gun, Hypertherm Power-Max 380 plasma cutter

Parts Used:
Hagan Street Rod Necessities hidden door hinges '50 Chevrolet Suburban PNHHH Retail price $395.00 (2 doors)

Total: $395.00
(prices from haganstreetrods.com and does not include labor, tax, shipping, or the cost of installation)

SOURCE
Street Rods By Dowdy P.O. Box 308 Dolan Springs AZ 86441 928-767-3171 www.desertconcepts.com	Hagan Street Rod Necessities 721 W. Monroe Street New Bremen OH 45869 419-629-1969 www.haganauto.com