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Bare metal 1959 Chevrolet Impala body with distinctive tail fin design, undergoing restoration
BBT Fabrications Builds a 1959 Chevy Impala
1. The 1959 Chevrolet that was the project’s base appeared to be in decent shape, but after stripping it became apparent that many repairs were necessary. A substantial portion of the original metal was replaced.
BBT Fabrications Builds a 1959 Chevy Impala
Part 2: Bringing Up the Rear
By Ron Covell
I

n this article, we’ll look further at the great work being done by Troy Gudgel and his company BBT Fabrications for their customer Eugene Bothello. The intention is to keep the character of an original 1959 Chevrolet but add a host of contemporary touches and ensure the fit and finish are brought to the finest level possible.

They started with a decent-looking car, but after stripping everything down to the bare metal, they decided to replace all the lower portions of the quarter-panels due to some previous substandard work. Sections of the decklid and tailfins had to be replaced, too. The original leading on the rear seams was removed, and the joints were re-leaded to achieve perfect contours.

A new rear bumper was made from scratch, and a rolled pan was added. The bumper was tucked snugly into recesses formed in the body panels, and some detail work was added in the rear, including uniquely shaped exhaust ports and a tasteful billet aluminum valence panel.

The taillight bezels were completely remade. Although the shape looks stock, a lot of effort went into making all the edges crisper and more uniform. New custom taillight lenses were also made.

A new fuel tank was made from stainless steel with a ribbed pattern that matches the floors, which we looked at in the last article. This tank is attached to the chassis with special crossmembers, which attach to the top side of the chassis, so it presents a seamless appearance when viewed from below. The custom filler neck is hidden behind the hinged license plate.

It is a delight to see work of this caliber being done on such a large, voluptuous car. You will see more articles that showcase the complexity of this top-level project.

Top view of the Impala's body, showing surface prep for primer and paint
2. The decklid and the tops of the tailfins were largely intact, but any questionable metal was cut out and replaced with new, full-thickness material.
Restored metal door panel with detailed welding to patch rust and damage
3. Here you can see how much of the left tailfin was replaced.
Rear quarter panel restoration with new metalwork replacing rusted sections
4. The lower quarter-panels had been repaired previously, but the quality was not up to the standard for this project, so the poor work was completely cut away.
Clamps securing a newly fabricated rear fender patch panel for the Impala
5. Patch panels for the front and rear of the quarters were fitted into place and marked for trimming and welding.
Precision-crafted rear quarter panel replacement ready for installation
6. The front and rear sections were TIG welded together on the bench, then metal finished before joining the quarter-panels.
Detailed welding of a new lower rear body section on the Impala
7. Here is the left quarter after the patch panels were welded into place. The joint is now ready for metal finishing.
Close-up of the lower rear body patch panel welded and ready for finishing
8. On the rear of the body, all the panels below the license plate recess were replaced with new metal. New bumpers will be built to fit snugly against the body.
Fabricated side sill replacement for rust repair, prepped for installation
9. New pieces of metal are shaped to round the corner between the quarter-panel and the rear rolled pan.
Lower body panel fabricated and welded in place, showing clean lines and detailed craftsmanship
10. The center of the new rear bumper is fabricated from three pieces of 14-gauge steel. The rear cap is plug-welded into place.
Close-up of a rear bumper seam with alignment pins during metalwork on a 1959 Chevrolet Impala
11. The corners of the bumper are shaped and trial-fitted into place. Note the smoothness of the finish. These parts will be chrome plated, so the metalwork needs to be perfect.
Fabricated tail section, showing a smoothed and welded end for the Impala's rear panel
12. Here, the upper and lower portions of one bumper end have been TIG welded together and are ready for metal finishing.
Restored Impala rear bumper corner, sanded to a smooth finish
13. This is how the bumper looks after meticulous smoothing and metal finishing. It looks as if it was formed from one piece of metal.
Detailed welding of a reshaped Impala rear bumper to achieve a custom fit
14. The recess in the quarter-panels is carefully shaped to match the contour of the new bumper, ensuring the gap is tight and consistent.
Seamless integration of the restored bumper and rear panel with smooth, flowing lines
15. Here’s the result, showcasing a nice, snug fit. This level of detail is incorporated in all aspects of the build.
Welded corner of the Impala’s rear panel showing the reconstruction of rusted areas
16. The Chevrolet factory used a lot of lead filler on the joint where the rear panel meets the quarters. The old lead was removed, and the seams were re-leaded to perfection.
Rear fender work showing a reshaped and cleaned section with smooth contours
17. The fins were also leaded to the rear panels. Again, the factory lead was removed, and the joint was re-leaded and meticulously finished to a high standard.
Fabricated rear diffuser integrated into the Impala’s underbody for a sleek, modern look
18. Subtle styling was added below the rear bumper. Two trapezoidal openings for the exhaust tips were added, and a billet aluminum valence panel was added between them.
Custom-fabricated exhaust cutout added to the rear section for a clean exit design
19. The return flanges for the exhaust openings are being fitted here.
Completed view of the custom rear diffuser, featuring louvers and exhaust cutouts for enhanced performance
20. Here, the CNC-machined exhaust bezels are fitted. This gives the rear of the car a nice, contemporary flair.
Custom-fabricated fuel tank assembly with ribbed details for improved structural integrity and aesthetics
21. A new 22-gallon fuel tank was fabricated from stainless steel. It will be held into place with its robust chassis crossmembers placed on the top so they will not be seen from beneath the car.
Installed custom fuel tank underneath a 1959 Chevrolet Impala, integrated with dual exhaust system
22. Here, you can see how the chassis, exhaust system, fuel tank, and rear valence work together harmoniously.
Close-up of the Impala’s trunk latch mechanism being installed onto a fabricated support bracket
23. A lot is going on here. A brace was constructed to support the decklid’s weatherstrip channel, incorporating the latch. It also supports the filler neck for the gas tank, accessed from behind the hinged license plate.
Digital CAD rendering of a custom tail light for the 1959 Chevrolet Impala, designed in Fusion 360
24. The new taillight lenses and bezels were CAD-designed and CNC-machined. They incorporate a shape like the originals, but all the edges have been made more crisp and uniform and are made to a much higher standard of fit and finish.
Rear view of a 1959 Chevrolet Impala in bare metal, featuring custom-fabricated tail lights and bumper refinements
25. Here is the tail end of the car with all the modifications completed. It retains the character of the original, but the details are refined and modernized.
SOURCE
BBT Fabrications
(217) 586-5699
bbtfabrications.com
Modern Rodding
VOLUME 5 • ISSUE 50 • 2024
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