When a customer’s classic Chevy C10 truck bed came back from the media blasters it was clear the custom widened inner fender arches needed some help.

Below shows the custom widened arches that were on the truck bed.  After media blasting, you can see that it was a poor custom job on this classic car from a previous restoration/custom job.

Custom Chevy C10 truck fenders

Results from media blasters. Previous custom work carried out to a poor standard.


Material overlapped, MIG welded, and body fillered over

After we took delivery of the truck bed from the media blasters, we had the customer check out the arches for himself.  After a brief study of the bad workmanship he asked me to make him a new set of custom arches for his Chevy C10 truck.

We always evaluate and look for the quickest, most economical way, to complete a job for a customer.  This particular job highlights this perspective.  The inner fender housing only needed to be 2″ wider than a standard factory pressing.  To take one aftermarket pressing, cut, add in 2″, and weld in two joint lines so close together, would cause a distortion problem in the metal finishing process.  This would also add a considerable amount of time to the project, not to mention the amount of welding to achieve this option, as opposed to another route.

The second option involves buying four aftermarket pressings and making them into two inner fender housings.  To make one custom inner fender for the left hand side you need two left hand  pressings.  The picture below demonstrates below a left and right hand pressing.

Custom Chevy C10 truck fenders

Reproduction donor rear fenders


So now we have the ingredients, lets operate!  We have two right hand pressings sitting on the table.  Take one pressing mark and cut the bolt flange off half an inch in from the edge.  Take the second pressing marking the  1/2″ lost on the first pressing + 2″ for the custom width  from the bolt pattern flange.  Cut to the line and tack the 2 sections together as shown below.


Custom Chevy C10 truck fenders

Mark and cut end flange off fender

Custom Chevy C10 truck fenders

Sections tacked together

Photos of custom widened Chevy truck fenders

Once tacked together, TIG weld, and metal finish to complete.  Once metal finished to this high standard there is no body filler required, only primer and paint.

Custom Chevy C10 truck fenders

TIG welded and metal finished


Custom Chevy C10 truck fenders

Custom widened Chevy truck fender metal finished

Custom Chevy C10 truck fenders

View of weld joint from inside the fender

So there we have it, a paint ready panel for this custom Chevy truck, with one weld line instead of two. We have initial extra costs for buying four panels, but did save a considerable amount of time and money with welding each inner fender panel only once.


Check out our other Chevy projects, and other classic, vintage, and antique cars from the categories on the right-hand side of the page.

Contact The Metal Surgeon for more car restoration information!  Look under the “About Me” page at the top.

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