Chevy Sedan Delivery 1950 / Click here to see the project

The Chevy Sedan Delivery has come to us for some fitting work on the doors and just some general fit and finish. This rear door is pretty rough, it will require just about starting over.

With the door removed, you can see that the Interior was started by someone. The inside of the Sedans is pretty roomy, If it’s done right. The door was pulled off to have some of the bottom skin redone. Doors for this vehicle are very hard to find.

Here you see two different doors, the owner found another to try to make one good door. Both doors will require lots of work. You can see that the door we took off the Sedan has been cut up. This was the result of trying to install hidden hinges.

The bottom of the door had been repaired with Galvanized steel, not a good idea. The bottom skin will be cut off and started over.

The skin was cut away, it was cut a little higher to remove some rust and dents. The new skin will be shaped and welded into place.

This is the backside of the Galvanized panel that was welded in, as you can see the penetration was terrible. The door has been sanded down and all the rust removed. Its now ready for the new skin to be formed and welded in.

The rear door of this Chevy Sedan is tough to find, almost impossible. The door skin is separated and needs to be tacked into place. The door is mounted on the Sedan and aligned with the hidden hinges, it needs to be shimmed to a good fit before it is welded.

The door skin has to be welded all the way around the door, the edges have to be finished to look good as new. You can use a Metal fill for any pin holes left over. This door will be good as new when finished.

The door skin is all welded into place, there is a new support welded behind the seem to give it support. The metal will be worked and metal filled to give it strength, we don’t want the panel to flex.

The customer wanted a third brake light below the rear window. Using just a slit is pretty common, but creating your own Chevy Bow Tie for a Third Brake Light… Nice! This will be a classy original custom feature for this car.


The door is almost finished, if you look you can see that the inner door skin was cut away to install the bracing for the hidden hinges. Now that the door is aligned and everything finish welded, the inner skin is welded back into place for support.

The door is all welded and ready for a little bodywork. After it has been worked to look new, a few coats of primmer sealer protect it.

All three doors are going to have shaved handles. The doors have hidden hinges and electric latches. The holes will have steel patches welded in and be ground smooth.

Here you see the front drivers door all welded up and ground smooth. the shot next to it is the rear door, it has been welded, smoothed and now has a sandable metal filler added.

The rear door and the shaved handes on the 50 Chevy Sedan Restoration are ready for sealer. Now the bodywork elsewhere can be addressed.

This is the engine compartment of the 50 Chevy Sedan. The Owner bought this car with the engine already done, but you never know what someone has built. 

The engine is being inspected, it runs rough, the valve train knocks and we’ve found fuel in the oil. about 2 quarts worth. This could be a lot of different things, so we will eliminate things one at a time.

The engine was checked for something that could cause fuel to be getting into the oil. The valve covers were removed and the valves were checked and re-adjusted. The plugs were pulled and replaced, the old ones were fowled. The carburetor was taken off and taken apart, the jetting was wrong for altitudes above 6000ft.

The gas tank in the 50 Sedan was held in place by a pool toy, lets remove that and make the proper kind of brackets. you see here a black angle iron  bracket with pads now bolted in place on each side.

The gas filler box area has a problem with water sitting and rusting, a hole was drilled and a drain was installed, you can see the small hole on the bottom right corner.

The picture on the left is a little hard to make out, this is the drain tube coming out of the gas filler neck box. this tube runs to the outside of the car. Up next is a hole in the firewall needing filled.

The correct way to fill any hole in sheet metal, is to cut a metal plug and weld it into place. We had to be careful, the fuse panel is right behind this hole. precautions had to be taken so nothing gets melted or burned.


The firewall hole is filled with sheet metal and ground smooth, the area is sanded smooth and filler is added to blend the area. Once the area is painted no trace will remain. This is the only correct way to fill a hole.

The Chevy Sedan was having a serious problem, the oil level continued to go up and up…Quickly obvious was the smell of gasoline in the oil. Further investigation led to the After Market fuel pump being bad. An internal leak in a fuel pump will definitely cause this kind of problem.

The door looks like its going to need some work. The wiring needs cleaned up and looking further, you can see the rust on the bottom corner of the drivers door. The only way to fix this properly is to remove the door.

You can see that the wirings also was done incorrect, these wire nuts should never ever be used on a car. Bad wiring is the cause for more fires in Hot Rods than fuel related issues.

The wires were removed from the door, you can see a wire loom that someone had installed. Unfortunately the loom has been damaged and can’t be used again. When the wiring is cleaned up this will be addressed.

Here’s a good look at the bottom of the door, once the paint and some of the Bondo was removed. It always amazes me why someone would do this, it really almost takes more work to cover something like this up than to just do it right.

The new sheet metal has been fabricated for the door corner and welded into place, the large flat area had some issues that needed to be addressed as well. Next is to add a light coat of filler to clean these areas up.

The 50 Chevy also has some rust on the front of the door to deal with, this is the opposite side of the Bondo mess. This metal will need to be cut out to make the correct repair.

After the rusted metal was cut away we can see the Bondo and rust built up. The area will be cleaned up to see if more repairs are needed. 

The damage was pretty minimal, the area is treated with a rust encapsulator and ready for the new metal to be fitted. A new piece is fabricated and tacked into place. The piece will get welded and ground flush to finish the repair.

The welding is completed, now a light coat of Body Filler is used to even out the surface and get it ready for primmer.

The repairs on the inside of the door are almost finished, the primmer was applied in this second photo once the door was finished. The universal power window regulator will be removed to investigate a problem next.

The door has been finished, primmered and hung back on the car. The wiring and window regulator will be the next issues to  be address.


This is a couple shots of the Universal Power Window Regulator. These units are very powerful, they have to be installed very precisely to operate correctly.  With further research we found that the unit has been damaged because of being installed incorrect. The plastic housing should be one piece, not broken between the two ends.

The new window regulators are in, therefore the doors can both come off and be disassembled. The old window regulators will be taken out and the process of mocking up the new regulators can begin.

The doors from the 50 Sedan are set side by side for the process. You can see the difference between the old window regulator and the new. The old one on the right is made of mostly plastic, the new one has been updated with a new design and steel shaft. Much stronger design.

A close up look shows the updated design. Unfortunately for us, the mounting design is different. The installation process will pretty much start from scratch. Also when a kit says its Universal and Easy to Install….It’s saying that you must cut and fabricate and be willing to re-engineer everything to get it to work.


While the doors are off, the old holes that are no longer necessary will be welded shut. The doors will be completed before they are hung back on the car.


This is the shot of both doors during the process. After the welding and grinding is done a little filler will be used to smooth out the doors. When all is done and the doors are back on, the wiring will be tackled one wire at a time.

The doors on the Chevy Sedan still need work, if you’ll notice, the door jambs have holes that are unwanted. All the old holes and rust repair needs to be gone over, there are old repairs that need to be fixed correctly.

The only true way to repair a hole on metal, is to put the metal back. Making metal plugs or patches and welding them into place is the correct way. The metal will be smoothed and primered when done.

A little bit of filler smooths out the grind marks. Once all the work is done all the areas will be sealed up and smoothed for paint. The rear door still needs a hidden latch and door popper installed.

Here’s an example of the passenger door needing metal work. This area will have new metal welded in and smoothed, the results are always great when you do things right!

The doors need attention as well. There are dings dents and holes that will need metal work and just a plain old dent puller. The doors will be fixed and smoothed, then the jamb areas will be sealed and primed.

The Owner of this 50 Chevy Sedan has decided to eliminate the wire looms that ran threw the doors. We will run wires into the door in a better way. The holes need to be welded shut.

The holes are all welded up and ready for primer. We decided to start investigating the cracks and Bondo filler. At some point there was a lot of bodywork done to this car. Looks like bondo over rust, we need to remove all the bondo from the rocker and see what it looks like.

Wow, ok what you see here is Bondo about 1/2 inch thick. It looks to be over twenty years old, but its covering rusty metal and old holes for trim. Fixing this with metal is always the right way, also it doesn’t take that much longer to do the job right!

This 50 Chevy needs to be fixed right, these cars are pretty rare. The best way is to cut out the cancer and make some new pieces, this isn’t bad enough to replace the entire rocker panel. This inside rocker needed to have a new piece made and welded into place first.

Once the inside rocker steel was replaced, the outside can be started. This piece is tacked into place, once its all welded up we can use the right amount of filler to finish it off.

Now that the drivers side of the 50 Sedan is done, its time to do pretty much the same thing on the passenger side. Now that the door is removed and the bondo, we can start to dig in and see just how bad things are. Looking at this, we pretty much just need to weld up some holes.

The panel had a lot of bondo, it looks like the panel was dented in and covered. Now that the filler has been removed, we can keep welding up some holes and start to pull the dents back into the proper shape. The studs are for pulling the dents.

The rocker panels on the 50 Chevy are all done. The loads of bondo have been removed, rust cut out and new metal welded into place. It took some work but the results are great. The door jamb areas are now primed to seal in the work.

It seems like we keep working on the doors, another hole filled and now they are ready to be sealed in with some primer. Once dry, the doors will be reinstalled…again.

Here’s the drivers side door jamb. All the work is done and it is being primed as well. We seem to be making pretty good progress on the bodywork phase of this 50 Chevy Sedan.

Now that the doors and rockers are pretty much done, its time to dig into the rear quarters of this Sedan. There is a lot of bondo on these quarters too, but why? we need to remove all of the body filler and see whats hiding.

Ok, now that we removed the passenger side bondo, and found a few areas of rust, its time to remove the filler from the drivers side. Above the wheel well we are finding fiberglass, covering a very large hole. The rust seems to be worse on the drivers side.

This 50 Chevy Sedan is a rare car, the work must be done right to bring this classic back into shape. The fiberglass was hiding some pretty good rust, they  don’t  re-pop  these quarters out of new steel. we will just have to make our own panels. The quarters for the most part are in pretty good shape. this looks worse than it really is.


The Sedan needs lots of metal work on these back quarters, The inside wheel wells are also rubbing on the tires. We will cut out any rust and replace the sheet metal, also we will fabricate a new inner wheel well plate that gives us more clearance.


The new sheet metal is all cut out and ready to be bolted back in place. The steel surrounding this area is in good shape. Next up is some exterior quarter work.


This is the view of the drivers side quarter panel, inside and out. The inner cover will also be remade for clearance. There’s just no easy way to fix rust problems like this. If you could order new sheet metal it wouldn’t be such a tough choice.


We cut out the rusted area, only to find more rusted area. The inner sheet metal will need to get cut back as well, all we are looking for is solid steel to weld against. These pieces will have to be fabricated and welded back into place.


The sheet metal needed to be replaced in sections, there was rust all the way to the inner cover plate. This new section has been formed and the new inner panel secured in place. Next is to start hand forming the outer 2 pieces for the wheel well.


The new sheet metal pieces have been formed for the 50 Chevy. The smaller of the two is the inner sheet metal skin, this is for structural strength and gets welded in first.


The New sheet metal pieces have been welded into place and are ground down, this is better than bondo filler covering things up. The entire area will start to get smoothed with thin applications of body filler.


The Chevy Sedan is starting to look much better, the filler has been applied and feathered out to fill in any low spots. This fender is now correctly done. The rest of the fender area will be gone over and be ready for a coat of primer soon.


That’s much better! The 50 Chevy now has a solid steel fender well area, the rust and bondo would have just kept giving this customer problems. Doing thing right isn’t always easy, but its what matters most.

The 50 Sedan has been on hold for a little while, now its time to get going on this serious rust and bodywork. The rust needs to be cut out and new metal welded in.

The huge areas of bondo are ground off so we can find any rust that needs fixed. It looks like most of the rust is close to the bottom of the vehicle.

The dents need to be located and the studs welded in place to pull the metal out. The body filler needs to be kept thin. This requires a lot more work, but its the right way.

Here’s a pile of rust from the old piece cut out. This is the passenger side in front of the rear tire. It looks pretty serious, but the metal is solid. We need to clean this area up new weld in some new metal.

Here’s a shot of the studs being welded in place. Everyone of the studs represents a dent or low area of some sort. The hammer pulls the studs and levels out the surface.

The metal is being cleaned. It takes some work, but we don’t have to cut out the entire fender. The second shot is the after shot, welded, ground down and light weight filler applied.

This is the rear section, studs are applied to the low areas. This is also the shot of the cleaned inner fender before we welded in the new metal. A special spray on weldable primer is applied before the new sheet is welded into place.

The back corners are real rough, pulling the metal out with the studs and applying filler is how to treat these areas. There are no real tricks to bodywork, just time and patients.

The filler on the sides is all smoothed out, we are just about ready for some primer to be applied. It’s a lot of work, but the end result is always worth it. I know it seems like the work is taking forever on the 50 sedan, we decided to spend more time when we do start working. Some of the most major work was done this week. We will continue the lower sections and then work our way to the roof.

The sedan is back in the body shop. We still have plenty of straightening on the body sides to do. The Sedan has come a long way since it got to the shop, the bodywork needs to be done before we can get this car into solid primer.

The 50 Chevy Sedan is a big project, but this is also a pretty rare car. The car is getting better looking all the time. Once we know all the outside is done right, we will be able to put a great paint job on this car.

The weather was good enough to bring the car outside for some air. The body work continues and the results are looking good.

The 50 Chevy is starting to look better everyday. Besides the roof, the major body work is pretty much complete.

This looks pretty good if you remember what we started with. This is a pretty big project, to get a body of this size straight takes lots of work.

The 50 Sedan still needs the body lines worked out, the doors and front end have pretty big gaps. The objective is to have the gaps fixed during the body work stage, before the paint goes on. Sometimes it involves removing fenders and doors to get the adjustments right.

The fender on the passenger side needs the mounts reworked. Because of the bondo and rust the mounts are either gone or not lining up, they will be re-worked so we can create the right body gaps.

The 50 Chevy has come a long ways. This car was a big pile of Body Filler when it came to us, today it’s done right and getting better every day. The good news, the lower half of the car is done with the major body work!!

I know the Owner of this car must be pretty excited! It’s taken a while, but the car is really starting to shape up. It’s now in the paint booth, this means the major body work on the lower half is done!! Now for some Epoxy Sealer to finish the bottom. The hood and the roof are next, this car needed a lot of work. The 50 Chevy Sedan is a pretty rare find, so the time and money are well spent!

The epoxy sealer has been applied, the bottom half looks great! The next phase will be to tackle the roof and hood. The bottom of the car will start getting blocked out, this will show any imperfections.

The 50 Sedan has come a long way, once we get the roof and hood finished the entire car will be in primer. This is a big car, lots of areas to get straight. The progress continues, the body lines look better than ever.

The hood is all striped, it looks pretty good. There is no solid rust or holes to fill. We will have plenty of body work to do, there is some old lead that needs to be removed carefully. 

The roof of the 50 Chevy will be the most challenging part, this is a big car. Removing all that paint will take time. We already know the roof has some serious dent to be pulled.

I wanted to show some bigger pictures, its easier to see what’s happening in these shots when you see more of the car. The paint is being removed while checking for body filler or lead.

Seeing the Sedan with the paint removed from the top of the car, kind of puts things in perspective. This is a BIG car, it took plenty of time and sand paper to remove all that old paint layers.

The roof skin of the Chevy looks pretty good, we found lead and plastic filler on the roof. We will need to heat and pull some areas, but the roof has no real major work to be done. Next step is the body work and get the rest of the car in primer.

Only a couple pictures, but the progress continues! The hood already looks fantastic. The car is looking straighter and straighter. We are in the process of heavy blocking, after the roof and hood are finished and coated, the fine blocking will begin. Take time and work for a really great paint job!

The 50 Chevy is getting the roof all fixed up, after getting it as straight as possible we are using a light weight filler to get it really straight. Everyone who see this car just loves it!! 

These 1950 Chevy’s are pretty rare, this is the first one in the shop. The roof and the sides are a ton of work, very large panels to get straight.

The sides are fairly straight, but we are coating them with the light weight filler. These will be the first things people look at when they see the car.

The filler looks heavy, but once its sanded down about 90% of it comes off, you could do small areas at a time, but it would take all day and be almost impossible to get the sides straight. This process is expensive and a ton of work, but the results are the best.

There’s no better way to get a car this big ready for paint, you need to tackle whole sections at a time. The process will continue until the car is ready for paint.

The top and sides have been a ton of work, there’s still a ways to go, but they looks great! This car looks a million times better, the hard work always pays off when you see the end results. Great paint takes lots of hard work at this stage to make things perfect!


Finally!! The Major bodywork is done! The body looks great and the car is all one color. The job has been pretty big and seemed to take forever, the car is ready for blocking and finish sanding.

It’s time to tackle the wiring mess in the 50 Chevy Sedan, this is what you see when you open the drivers door and look under the dash. You can see the mess of wires, but this is a brand new Painless wiring harness… OH Wow, yes someone tried to wire this car without experience, they must have gotten in over there heads.

Knowing where to start, or starting over is the real question! If this wasn’t a very expensive harness, we would tear it all out and start over. It may take some time, but i think we can slowly clean things up. The picture on the right shows the main connector to the steering column. Left alone, this would stop working. Even worse, there could be a short that would cause a fire!

We had to pull the steering column out, the wires were way too short. We will lengthen them and clean up the column while its out. The picture to the left is looking threw the hole where the gauge cluster goes, you can see the mess continues. We will basically take and re-run all the wires one at a time.

Looking close you can see wires being grouped together, then wrapped to keep things much cleaner. Things already look much better. The column was sanded and re-painted. The wires have been replaced and are now long enough to install the column back properly.

The wiring under the dash has been gone threw, now to clean things up else where. The cover behind the seat houses the battery, cut off switch and various terminals. These wires need to be ran neater and secured.

The customer has decided to add some base to his sound system, without adding any huge boom box or exposed speakers taking up room. The sub-woofer enclosed in the amplifier has become popular with Hot Rodders looking to save space and give a clean appearance.


Data Loss…..


The 50 Chevy will need to come apart. The front windshield needs to come out, the dash needs some bodywork before we can start painting all the interior pieces. The front clip will be removed so we can get the firewall smoothed out for paint.

With the front clip off, we can smooth the firewall and clean up all the jamb areas for paint. Once most of it is done, we will pull the front windshield and finish the interior dash.

Trying to get the dash fixed and sprayed correctly would be impossible with the front window still in. It’s always a risk when you pull used glass, but if you want it done right, it’s a must.

Now that the dash, door jambs and firewall are ready for paint, we can tape things off and get ready to spray. The Sedan is getting painted a green metal flake. The color is great! Bodywork has to be perfect to get a dark color to look good.

All the doors and small dash parts will get painted at the same time. Once the pieces have had time to cure, the car will get reassembled for paint. The Sedan will require lots more paint because of its size.

Here’s a shot of that metalic green color, the color is a darker green and has lots of depth to it. This is going to be a very cool custom when it’s all completed. Probably not going to see another 50 Chevy like this one anywhere.





























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