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side profile view of 1958 Chevy Fleetside wheel
Boneyard Brainchild
Fleetside Taillights for Stepside Fenders
 BY “Rotten” Rodney Bauman
“It’s

all been done before!” Yes, we’ve heard that said, but let’s be open-minded here. Granted, walking through a custom car show won’t likely trigger novel notions, but walking through a wrecking yard still can. For Colten Hart, of Kalispell, Montana’s Vintage Soul Garage, that’s exactly how his custom taillight treatment came to mind—by walking 40 acres of elderly cars and trucks. We’ll circle back around to that, in just a bit or two.

For now, before we go much further, know this about Colten Hart: At age 28, he’s a builder with a full bag of tricks. Custom body- and paintwork are his specialties, and he’s helped a good number of other builders over some humps. Lately, Hart has been assisting Kalispell collector, Bob King, with a restomod-style 1959 Chevy ice cream truck build. At the same time one of his own projects is on the lift in King’s shop. Long story short, Hart has purchased an unfinished 1959 Chevy Stepside shorty that he’ll rethink as necessary, see through, play with, and perhaps peddle one day down the road. (At the time of this typewriting, Hart’s personal pickup project is receiving some needed attention, as he’s pulling off a good save. From here, however, let’s focus only on the aforementioned custom taillight treatment.)

Through the existing white paintjob, the old truck’s Stepside fenders appear to be decent, for used OE parts, anyway. In its current stage of incompletion, the project’s taillights have not yet been thought out. The easy way would be to order up some new reproduction Stepside-type lights from Brothers. For Hart, however, choosing the easy way doesn’t come so natural.

So, back to the boneyard. During a routine visit to Cut Bank, Montana’s Rustless in Montana, Hart came upon the shell of a 1958 Chevy Fleetside pickup. Recognizing shapes, as well as their potential, he then birthed the notion to graft a pair of Fleetside-type taillights to his good-enough, used Stepside fenders.

At the shop the next day, it was first things first, as a parts order was placed. From that point on, Hart’s custom body modifications would be based on a shiny new pair of LED taillight assemblies, available through Brothers, which outwardly appear to be exact reproductions of the 1958-1959 Chevy Fleetside units. When those parts arrived, Hart commissioned the local sheetmetal shop to roll out a pair of 18-gauge steel tubular tunnels to match the od of the shiny new taillight bezels.

Skipping ahead, we’ll end up with a one-off custom taillight treatment, all in compatible, same-vintage, Chevy pickup style. On that note, you’re invited to stick around as Hart openly divulges the step-by-step procedure for the replication of his own boneyard brainchild. Somewhere between Stepside’ing Fleetside?! The end result deserves a clever name of its own … we’ll leave that open for suggestions.

Fleetside taillights in the weeds
1. Here in the weeds at a favored Montana honey hole sits the initial inspiration for what’s to follow—Fleetside taillights for Stepside fenders.
the OE fenders with white paint and primer
2. Back at the shop, the OE fenders seem worth working with. Below the white paint, substrate primers are pretty thick. There’s also a B-side undercoating, so we’ll see.
Colten Hart grinding and exposing the area to be modified
3. As exploratory grinding gets underway, Colten Hart is optimistically exposing the area to be modified—with a ridged disc affixed to an electric grinder.
Hart laying out preliminary guidelines with a sharp straightedge and a dull sharpie
4. With a sharp straightedge and a dull Sharpie, Hart lays out preliminary guidelines. To accommodate tubular taillight tunnels, the cutaway area must taper toward the front.
Hart tracing around the outside using only the bezel of the new Brothers LED taillight assembly
5. Using only the bezel of the new Brothers LED taillight assembly, Hart traces around the outside to roughly establish another guideline. This can still be adjusted as need-be.
side-to-side measurements of the compound-curvaceous areas
6. By now there have been many side-to-side measurements taken. For these compound-curvaceous areas, however, there’s still some eyeball engineering required.
Hart making his initial incisions after moving from the grinding room floor
7. Moving to the grinding room floor, Hart makes his initial incisions. As it turns out, he’s deadly accurate with a plasma cutter.
Hart proceeding in short increments checking his work as he goes
8. Rather than cutting away the entire unwanted expanse at one time, Hart proceeds in short increments, checking his work as he goes.
the rounded-end incision receiving some fine-tune grinding using a ridged disc
9. Again, using a ridged disc, the rounded-end incision receives some fine-tune grinding. You’ll notice as we go that Hart uses electric grinders exclusively throughout this job.
Hart looking at the cuts down with the plasma cutter
10. So far there’s only been that bit of grinding that we’ve just seen. The cuts we see here were done with the plasma cutter. For the stage we’re in, we have a tight fit.
18-gauge steel tunnels ready for a trim
11. The 18-gauge steel tunnels won’t remain tubular much longer. At the forward end it’s now time for a trim. For this, a poster board template is useful as a guide.
Hart slicing away the first unwanted section of the tubular tunnel with an electric grinder
12. Again, with the same type of electric grinder, this time outfitted with a cutoff disc, Hart slices away the first unwanted section of this tubular tunnel.
pie slices created for the forward end of the tunnel
13. To create a tapered point for the forward end of the tunnel, pie slices are required. There’s no fancy math going on here, but Hart’s educated guesswork should be good.
Hart removing small pie slices while cutting along the lines
14. Cutting along the lines, Hart removes small pie slices. You might recognize the Berger-brand welding magnets. Yes, there’s a brand-new Harbor Freight store in Kalispell.
an initial test-fit confirming the pointy fingers need more relief
15. This is just an initial test-fit. Here testing confirms that the remaining pointy fingers could still use a bit more relief for correctly tight gaps and easy shaping.
the tube’s forward-end pointy fingers receiving a second shave
16. So, here the tube’s forward-end pointy fingers receive a second shave. For this type of trimming, too little is better than too much. That’s why Hart takes this in steps.
closeup shot of Hart working on the tapered point
17. Hart’s got his MIG triggered. Providing you’ve brought your helmet, take a look just below the arc. See the nice tapered point now?
closeup shot of the plasma cutter being used by Hart
18. This far along, it’s safe enough to go actual size with the opening. Once again, the plasma cutter comes into play.
a pretty decent fit being shown up close held in place by Hart's hand
19. Held in place by hand, we can see a pretty decent fit. We can also better visualize what this’ll actually look like with abbreviated Fleetside body lines.
Hart tackling some welding and making use of the shop’s MIG machine
20. Again, making use of the shop’s MIG machine, Hart tack welds the new section to the used fender. The bulk of this welding will be done on the fender’s inner side.
Hart on his knees on the concrete floor using the shop's MIG machine
21. By now you’ve likely noticed that Hart doesn’t baby his knees. He’s young and able to work that way now, but someday that hard concrete won’t feel so comfy.
a fleet of portable work stands within reach in the workshop
22. All the while, there’s been a fleet of portable work stands right within reach—and I’m fixing to ask him to use this one here.
Hart beginning the stitch welding to prevent any distortion
23. Now on his feet, with his work at a comfortable level, Hart begins stitch welding. To prevent any possible distortion, he’s cooling with compressed air as he goes.
Hart grinding his stitch welds smooth for a factory appearance
24. Next, he’ll grind his stitch welds smooth for a factory appearance, even though this work will be hidden on the fender’s inner side.
closeup of the backside, or business end, of the new Brothers LED taillight assembly
25. Here’s the backside, or business end, of the new Brothers LED taillight assembly, complete with Hart’s own fabricated mounting tabs.
Hart using masking tape so the mounting tabs can be tack welded into place
26. Providing he works quickly, masking tape will locate the assembly so the mounting tabs can be tack welded into place.
Hart making three quick MIG zaps then removing the taillight away from the next bit of welding
27. Three quick MIG zaps later, the taillight assembly must be removed and rushed to safety—pretty much anywhere away from the next bit of welding.
a clear view of the taillight assembly back on the bench
28. With the taillight assembly back on the bench we get a clear view of the tack welded mounting tabs.
Hart satisfied with fitment and proceeding with the final welding
29. Now satisfied with fitment, Hart proceeds with the final welding of his taillight mounting tabs. At this stage the metalworking part of this job is just about complete.
Hart final product needing some filler work and usual priming
30. Of course there’ll be some filler work to follow, as well as the usual priming, blocking, and so on.
side profile shot of Hart's work all done and completed
31. By the way, we’re still open for suggestions, but for now, Stepside’ing Fleetside will have to do!

 SOURCEs

Brothers Truck Parts
(800) 977-2767
brotherstrucks.com

Harbor Freight Tools
(800) 423-2567
harborfreight.com

Vintage Soul Garage
vintagesoulgarage@hotmail.com