Chevy Crew Cab Dually

[makaveliks]

Bumper drop

Thanks for the compliments! I've been looking and have not yet seen one of these converted into a dually, or even an HD. I like having something different, and I also own a Chevy HD! Maybe this will be the first?

Not much time today. I had about an hour after work. I did manage to get the bumper cut and dropped. I just have it braced right now. Overnight the styrene will have plenty of time to bond very well before I start putting my fat fingers all over it again. Perhaps tomorrow I'll have time to start the end cap fillers. Once the caps are done and I brace the bumper in the center so it doesn't flex, I will cut out the grill opening and begin the new big mouth HD grill.

 

[makaveliks]

bumper smoothing

Today I made my bumper fillers and blocked them smooth. Still require some minor gaps filled and a little more reinforcement on the back before I'll get to the cutting out the center. I also trimmed off the lower air dam off the bumper... I know at least my HD work truck doesn't have that!

 

[malibulvr]

That body looks amazing, is there a tutorial somewhere that shows how to work with this stuff? Does the styrene come in different thicknesses?

 

[makaveliks]

I do not know if there is a tutorial anywhere. I learned by reading threads like this and then finding some styrene and started with something easy. I built a slide in camper first, now this. It's really very easy. It does come in different thicknesses and shapes. I got my sheets from here:High Impact Styrene Sheet | U.S. Plastic Corp.

As far as shapes, Evergreen makes stuff like that. Diffrent shapes such as tube, rod, and angles can be used for structure or whatever feels fitting. If you have a train modeling shop or section in your LHS for that, they probably have the evergreen stuff. It can also be purchased online at places such as Tower Hobbies. They come in small packages. They also have sheets, but they are very small and in that respect get very expensive when doing large projects. Plus you dont have very large sheets to work with.

For cement I use Plastruct Bondene I buy on Tower Hobbies. It is a thin liquid and works for ABS and styrene. You push 2 pieces together, brush some along the seam and it wicks through the joint. It then takes a few seconds to begin sticking and about 1 - 2 hrs to fully harden completely. It essentially melts the 2 parts together and is then essentially one piece again.

To cut it, you can use anything really. I usually use scissors for anything up to .060" thick. I sometimes also use a dremil, exacto knife, and tons of sandpaper. You can glue stuff al day, but most of the results come down to the sanding and finishing work.

That's all you really need to know! Once you have some stuff to begin practicing with, the sky and your imagination is the limit!

EDIT: OOPS! almost forgot another very important part! A cheap heat gun! You can heat the styrene to bend it or curve it. Just heat it to soften it, then bend over stuff I find around the house that is a close angle or curve to what I need.

 

[heinie_21]

lookin good! love the hood man!

its funny, with the bowtie off, the grill reminds me of a Ford raptor!

 

[Hoosierdady]

lookin good! love the hood man!

its funny, with the bowtie off, the grill reminds me of a Ford raptor!

Sure enough does, ha. Hadnt noticed that until now.

 

[ColquittCustom405]

flawless thus far. Make sure to cut the hood open and build the scale duramax! Suscribed."thumbsup"

 

[makaveliks]

Grill

Had some work this morning, got out and changed out the bathroom sink for a nicer one and new cabinet, lighting, mirror, and vanity. Then I had about an hour left to work on this. I cut out the grill opening, then began to make the grill! Now I'll let these pieces cure real hard before I move on.

Here's the stock 1500 grill.

And here's the beginning of the new HD one!

 

[heinie_21]

amazing so far!! I vote dont make it a dually though. or if you really need a dually, sell me this body first, then make a dually

 

[Desert Rc]

X2 hold off on the dually. Tough to make "right"....body work is very good. "thumbsup"

 

[makaveliks]

Thanks for the votes, but I'm pretty set on making it a dually. I realize it will be tricky to get the rear bedsides and fenders right, but I'm ready for the challenge! Besides, I already spent an arm and a leg on the wheels/tires! LOL

 

[indyrado4]

Judging by the styrene work so far, the bedsides will turn out fine! Have you decided on a final color?

 

[makaveliks]

yup... Plain Jane white work truck, like my 1:1 2500! I am also planning the commercial cap and may attempt a styrene brush guard, after all I don't plan to beat this so I don't forsee it actually NEEDing a strong one! LOL

 

[makaveliks]

More grill

Today I did a little more on the grill. I cut a piece for the upper half of the grill shell, and one for the lower half of the grill shell. Now it is the proper thickness to match the grill shell on the hood. I also began sanding it to it's final shape. Now all the angles and curves are correct on it. Next I just need to round the edges of the grill openings, add the chevy emblem, and the louvers. I'm going to have to pay extra attention to the grill shell and bumpers as they will painted with Alclad chrome paint and any imperfections will show through. The rest of the body will have a thicker duplicolor paint and tiny imperfections will not be so noticable.

 

[KryptoniteKummins]

could you hit the grill with high build primer first, sand it down quick to show the low spots than spray it with the chrome after everything has been filled and evened out?

 

[makaveliks]

Yes, that would be possible, but I still prefer to have the work as smooth as possible before that because even high build primer takes many coats and lots of sanding to correct imperfections that can be avoided in a more time effective manner with more careful build and assembly. I will still be priming and sanding smooth even after taking these precautions, and hopefully that step just goes much faster with better results.

 

[Hoosierdady]

great job here man. The new grill looks alot better btw. Go full on dually, FTW.

 

[makaveliks]

grill louvers

Yesterday I made the chevy emblem for the front that still needs some detailing and beveled the inner opening of the grill shell.

Today I made my grill louvers. I cut all the cross pieces, then notched the 17 vertical pieces so the horizontal pieces snap in. I then applied my Bondene to bond them all together. Tomorrow should be cured all nice and hard so I can sand the front smooth and to fit the back of the grill shell and bond it in. I also took the next 2 days off of work so I can be here when an electrician works on our house, so I will have plenty of time to begin converting the bed into a 8ft dually box.

And here's how my work area looks up to this point. Whatever falls on the floor gets swept up and goes in the trash. Whatever lands on the table stays there to use for filling gaps or smaller parts.

 

[KryptoniteKummins]

damn talk about SERIOUS attention to detail. i would have just grabbed some tiny chicken wire or something and gave it the "aftermarket look". Really diggin' the progress!

 

[makaveliks]

damn talk about SERIOUS attention to detail. i would have just grabbed some tiny chicken wire or something and gave it the "aftermarket look". Really diggin' the progress!

Thanks, I actually counted the louvers on my truck so I have the correct amount to look correct! LOL