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1938 Divco custom full body fabrication raw aluminum hot rod
1. This truck is completely hand crafted from aluminum but styled to have the general appearance of the classic DIVCO delivery truck. We’ll take a close look at how this project was started.
Laying the Foundation typography
Part 1: The SaltWorks Custom-Built DIVCO Project
By Ron Covell
DIVCO

delivery trucks were an American institution. They were built by the Detroit Industrial Vehicle Company from 1926-86. If you were around during that time, it’s likely that you saw milk, bread, and other commodities being delivered to people’s homes in these iconic vehicles.

While there are still some DIVCO trucks around, few of them are in good condition, as most had a hard life.

One individual undertook the project of resurrecting one of these venerable trucks in a hot rod style, but for various reasons the project was never finished. The owner took the project to Saltworks Fab in Sarasota, Florida, with the goal of having the project finished there.

A thorough inspection of the project revealed so many sub-standard areas that would require revision or replacement that the owner came to realize it really made better sense to start over; Saltworks suggested doing the entire build from aluminum. Aluminum has several advantages over steel: it’s lighter, easier to form, and doesn’t rust.

Roadster Shop built a stout new chassis for this project, which was considerably modified by Saltworks. It is based on a Generation III Hemi, built by Bouchillon Performance Engineering, with the transmission prepared by Bowler Transmissions. The rear axle was built by Strange Engineering and air suspension is used front and rear, which will allow the truck to rest literally “on the ground” when parked. The wheels were custom made by Curtis Speed.

The body is constructed over a sub-structure made from specially formed aluminum channel, with a contoured floor fitted on top. The framework for the body was made from custom-formed box sections, outlining the window and door openings. With this sub-structure completed, the body skin panels could be started.

While the sides of the body look flat, they all have a subtle contour, so great care was needed to correct the shape of each panel during the fabrication process. After the body sides had been constructed and positioned on the body, a recessed reveal was made to fit on each side, and then inset into the panels. Custom trim will be made to fit in this reveal, which will go a long way toward giving the truck a contemporary look while paying tribute to the traditional DIVCO styling cues.

1938 Divco floor pan structure aluminum bracing and weld layout
2. After the custom chassis for the truck was built, a stout sub-structure was made for the body, based on specially formed aluminum channels and flat aluminum plate.
1938 Divco transmission tunnel hand-formed aluminum interior sheet metal
3. A complete floor was built to fit on top of the channel subframe. This required lots of bumps and steps to clear the mechanical components.
1938 Divco transmission tunnel mockup with clamped layout straps
4. Here a simple template is made from strips of sheetmetal, making a guide for forming the transmission cover.
1938 Divco aluminum trans tunnel and center console shaping process
5. This is the cover for the transmission and bellhousing, formed from heavy-gauge aluminum sheetmetal.
1938 Divco rear suspension mockup with four-link and Wilwood disc brakes
6. The kickup in the floor over the rear axle assembly was an intricate fabrication project. Great care was taken to ensure good fit and finish both inside and out. Note the long-travel air suspension unit fitted to the rear axle housing, which will allow the truck to be lowered dramatically when parked.
1938 Divco custom rectangular aluminum tubing fabrication detail
7. All of the structural members for the body had to be custom fabricated to achieve the specific sizes required. TIG welding is used exclusively for this project.
1938 Divco rear body framework aluminum skeleton and wheel tubs
8. Here the structure for the body is largely in place—providing a mounting surface for the sides of the body, doorjambs, and window openings.
1938 Divco hand-formed aluminum body corners for lower trim transition
9. Special curved box sections were fabricated to join the body sides to the rear structure.
1938 Divco body post and lower quarter aluminum assembly mockup
10. The rear panel is being mocked up here. The hinges for the rear doors attach directly to the box sections, providing maximum rigidity.
1938 Divco rear cabin sheet metal layout inner wall structure
11. Here most of the interior body panels have been fitted and attached. Note the crisp, tight joints everywhere.
1938 Divco upper rear quarter window trim clamped for test fitting
12. A special reveal was formed for the sides of the body. The final placement is being dialed-in here.
1938 Divco rear quarter panel body filler and sanding in progress
13. The reveal has been welded into place, and the long joints are being carefully metalfinished. The red dye on the metal is an aid for finding any low spots, which are meticulously worked up until everything is smooth. The sides of the body look flat, but they have a subtle crown.
1938 Divco rear cargo floor section bead-rolled and welded panel
14. A special insert was made for the lower rear body panel. A snug recess was formed for mounting the insert.
1938 Divco raw aluminum trim strips prepared for rear fascia
15. This complicated stepped panel will become part of the doorjamb for the rear doors.
1938 Divco bead-rolled trim insert clamped for tail panel fitment
16. A dipped section was formed in the center of this panel.
1938 Divco tailgate panel aluminum assembly with bead detailing
17. Here the doorjamb is being fitted with the body and the internal structure.
1938 Divco lower corner weld bead detail for trim insert
18. The corners of this junction required precise fitting, but you can see that everything is perfectly aligned. With careful welding and metalfinishing, the result will be impeccable.
1938 Divco rear barn doors CNC-cut reinforcement and panel braces
19. Here the frames for the rear doors have been assembled and partially fitted.
1938 Divco rear barn door interior aluminum panel with X-brace reinforcement
20. At this stage, the outer skin has been attached to the door, and the action of the hinges and latches can be tested.
1938 Divco raw aluminum roof skin panel with rounded edge and ribbed stamping
21. The roof on this truck is enormous and had to be constructed from many separate pieces. Most of the roof is metalfinished here with just a few small areas left to complete.
1938 Divco aluminum roof skin test-fitted to body with clecos installed
22. At this stage, the roof panel is completely smoothed and ready for joining to the windshield header panel and the body sides. Next time we’ll look at many more of the intricate details on this dazzling project.
SOURCES
Bouchillon Performance Engineering
bouchillonperformance.com
Bowler Transmissions
bowlertransmissions.com
Curtis Speed
curtisspeedwheels.com
Roadster Shop
roadstershop.com
Saltworks Fab
(941) 914-5536
saltworksmfg.com
Strange Engineering
strangeengineering.net
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