1938 Chevrolet Pepsi Truck Custom Build – Part 1 This is part one of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in this post we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post three, we cover the chassis build and drip rail removal. In post four, we show you the process of metal finishing the fenders. Post five takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel. Post six takes care of the lower cowl metal and left hand front fender. Post seven covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels. Post eight looks at how the custom hood was created to open by pulling forward instead of the original butterfly design. We’ve began an exciting custom Chevy truck project for the Pepsi bottling company. We were commissioned by Newberry Motors GM dealership to undertake the custom metal work and restoration in their home town of Newberry, MI. After spending 7 weeks there, we completed the first stage of the metal work build. After discussions and meetings, the owner and Newberry Motors decided to send the truck back with me to my shop in Denver, Colorado. This is exciting for the Metal Surgeon as our new goal is to complete the whole project and deliver back to Michigan completed and ready for the 4th July Michigan Parade next year. So, let’s tell you about the 1938 Chevy truck and what we’ll be doing to the truck. The objective is to have the truck drive like a modern vehicle while in keeping the classic looks and style. On our arrival in Newberry, a freshly built chassis with a new drive train was ready and waiting to mount the dismantled cab and components onto. As mentioned, the overall look of the truck will be kept in line with the original look, but with subtle custom touches. The planned modifications are as follows: a one piece hood with using the original hinged hood and custom side panels, making the split cab into a one piece cab, solenoid doors, Air conditioning and heating, cowl vent removal, drip rail removal and, a custom bed. Other work includes the restoration of the fenders, running boards, cab, and radiator panels. Here are the first photos of the project before the dismantle. Thanks for checking out the post. So here’s our fine original 1938 Chevrolet truck in the showroom of Newberry Motors GMC Dealership. Side profile of the Chevy truck. Original, but worn interior. The cockpit before our custom treatment. Behind the cab, sporting the original bed. Take note of all the original features, as some will disappear. Check out the center hinged hood and side panel mechanism. This will be replaced with a full custom look. This is part one of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in this post we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post three, we cover the chassis build and drip rail removal. In post four, we show you the process of metal finishing the fenders. Post five takes us through the panel restoration of the original inner grille housing panel and a custom touch of deleting the cowl vent panel. Post six takes care of the lower cowl metal and left hand front fender. Post seven covers the toe board panel, door lock upgrades, and mainly the upgrades to the inner fender support panel; this panel has to be heavily modified to take the new location of the hood side panels. Post eight looks at how the custom hood was created to open by pulling forward instead of the original butterfly design. 11 Responses Restoration of the inner grille panel and custom removal of cowl vent | The Metal Surgeon November 16, 2013 […] is part five of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post […] Custom touches for 38 truck to support hood modification | The Metal Surgeon November 26, 2013 […] is part seven of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post three, […] A custom forward moving hood fabricated for a 38 Chevy truck | The Metal Surgeon February 19, 2014 […] is part eight of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post three, […] Cowl and front fender repair and restoration on 38 Chevy truck. | The Metal Surgeon February 19, 2014 […] is part six of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post three, […] Front fender restoration: 1938 Chevrolet Pepsi Truck Custom Build Part 4 | The Metal Surgeon February 19, 2014 […] is part four of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post […] Customization and restoration of a 1938 Chevrolet truck. | The Metal Surgeon February 19, 2014 […] is part three of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In this […] Customization and restoration of a 1938 Chevrolet truck. | The Metal Surgeon February 19, 2014 […] is part two of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In this post we look at the individual truck parts that make up the front end […] Fabricating a custom firewall panel and repairing the cowl style line. | The Metal Surgeon May 5, 2014 […] ten of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […] Custom hood fabrication for 1938 Chevrolet Pepsi Truck | The Metal Surgeon May 8, 2014 […] nine of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […] Creating a repair panel for a 1938 Chevy Truck Grille Shell | THE METAL SURGEON December 9, 2014 […] of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […] Custom interior AC/heater vent system for a 38 Chevy truck | THE METAL SURGEON September 13, 2015 […] of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […]
Restoration of the inner grille panel and custom removal of cowl vent | The Metal Surgeon November 16, 2013 […] is part five of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post […]
Custom touches for 38 truck to support hood modification | The Metal Surgeon November 26, 2013 […] is part seven of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post three, […]
A custom forward moving hood fabricated for a 38 Chevy truck | The Metal Surgeon February 19, 2014 […] is part eight of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post three, […]
Cowl and front fender repair and restoration on 38 Chevy truck. | The Metal Surgeon February 19, 2014 […] is part six of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post three, […]
Front fender restoration: 1938 Chevrolet Pepsi Truck Custom Build Part 4 | The Metal Surgeon February 19, 2014 […] is part four of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In post […]
Customization and restoration of a 1938 Chevrolet truck. | The Metal Surgeon February 19, 2014 […] is part three of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In post two we look at the individual truck parts that make up the front end build. In this […]
Customization and restoration of a 1938 Chevrolet truck. | The Metal Surgeon February 19, 2014 […] is part two of a series of posts on this highly custom 1938 Chevrolet Truck restoration, for the introduction to the project see part one. In this post we look at the individual truck parts that make up the front end […]
Fabricating a custom firewall panel and repairing the cowl style line. | The Metal Surgeon May 5, 2014 […] ten of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […]
Custom hood fabrication for 1938 Chevrolet Pepsi Truck | The Metal Surgeon May 8, 2014 […] nine of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […]
Creating a repair panel for a 1938 Chevy Truck Grille Shell | THE METAL SURGEON December 9, 2014 […] of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […]
Custom interior AC/heater vent system for a 38 Chevy truck | THE METAL SURGEON September 13, 2015 […] of a series of posts on this highly custom 1938 Chevrolet Truck restoration, in post one we introduce you to the project and the custom features to be fabricated. In post two, we look at the individual truck parts that make up the front end build. In post […]
