Big Bertha Build thread x2

[buggy5872]

Well this is a redo of the Big Bertha build thread. My picture host is now gone and my other thread has not puictures now. I will be cutting and pasting from the other thread since I can not update my old posts. Hopefully it will go quickly but the hardest part is remembering what pictures were where.

[buggy5872]

I have had many request to do a build thread on Big Bertha so here goes.... It all started one rainy day in June 2011. We were camping in our 1967 Serro Scotty 13' camper. The wife, 2 kids, 1 dog and myself were jambed in there due to a down pour. After about an hour the rain stopped. We got out and were walking around looking at all the people camping in big 5th wheel campers and enjoying the rain more than we did. The wife said that it was time to get one of those big campers. I told here we could get one if I could build a truck to pull it. I had been thinking and planning Big Bertha on paper for years but never had a reason to have something so big. She agreed and the hunt was on for the perfect truck. I found several out west but it would cost a small fortune to get them to PA. I ended up finding her on the "HAMB" web site. 1957 Chevy 5700 Low Cab Forward truck. She was only 4 hours away. I hooked up the trailer and my dad and I headed out too get her. Here is what she looked like when I got her home.

[buggy5872]

The next step was to figure out how to fit all of us in the cab. I had planned on making it a crew cab so I needed to start digging through my stash of parts, or as my wife calls it "that junk you really do not need to keep", and start figuring it out. I stripped the cab off the chassis so i could get it in the garage.

[mygmctruck]

How about addinmg an extended cab on that puppy ?

[youngrodder]

Originally Posted by mygmctruck

How about addinmg an extended cab on that puppy ?

You obviously didn't see this build the 1st time around. Stay tuned it gets much better than just adding an extended cab.

Marc

[buggy5872]

I started researching axles, chassis, and engine options. I settled on the GMC W4500/Isuzu NPR for several reasons. The frame width was the same as the original, front axle is only 1" wider than the original, wheel bolt pattern is the same as the original 57 (its 6 on 222.25 mm but works out the same as the 6 on 8.75) and they are every where. I looked at all the medium duty chassis but the axles were too wide. I found a 2003 GMC W4500 HD with 73,000 miles on it. It had a 350 vortech with a 4L80E tranny. So I bought it.

[buggy5872]

I then built a rack the same width as the frame and bolted the original front frame mounts to it. Set the cab and calmped the rear mounts. Out came the sawsall. No turning back now. I had a 56 GMC cab that was in pretty good shape so it became the donor for the back half. After a couple hours here is what I had.


I moved the original rear mounts to back of the gmc cab and used them to slide the cabs together and apart about 50 times as I cut and figured how it was all going to work. I did all the planning I could up front but until I got into it I did not know exactly what I was doing. I even thought that this was going easy and I would be done in no time.....boy was I wrong.

[buggy5872]

Next came the rear doors. I had thought about them but really had no good plan for them yet. I was looking at how the original doors were hinged and decide to go ahead and try to use them. I first thought about mounting them with no B pillar but quickly decide to give that up due to the door swinging forward and the front doors not being able to open. The other issue was the cabs become more narrow at the windows as you go toward the front windshield. I sliced and diced a few doors be fore I had something I thought would work. I decided to make them suicide doors for easy of hinge mounting and they are just cool.

I had seen some other crew conversions on TF trucks that had used full doors on the rear and did not look factory so I wanted to make sure it looked good enought to maybe be factory.

[arturo7]

Good gracious, a frankentruck!

[_Ogre]

it's just as sexy the 2nd time around

[RINC]

Originally Posted by _Ogre

it's just as sexy the 2nd time around

X2 !

[buggy5872]

Now that I had measurements, I could cut out the firewall and front floor section and make it all work. I wanted to use all the wiring, heat/ac and dash from the GMC. I wanted to use everything in case we have problems out on the road, I can give the vin for the GMC and they could order the correct parts to fix it.




I made the center section of the floor the same width as the engine so it could be removed to work on the engine. The engine ended up completely under the floor



At this point I hoped it would all fit because I had no way of sitting the cab on the chassis to test fit. the first time it was set on the chassis was after it was painted.

[buggy5872]

I needed to change the dash to the 56 GMC dash in order to use the gauge cluster from the newer truck. Changing the dash is no small task in these trucks. drilling out a ton on spot welds was in order. I cut and fit everything in the GMC dash before I welded it into the truck. I even had to french in one AC vent beside the glove box door because I ran out of room.

[buggy5872]

Now that most of the fab work was done on the cab I focused on getting the rear doors finished. I used power window units from Balls power windows. They have some nice units that work well for flat glass. Then it was on to the body work.



and it seemed like it would never end.

[Kim57]

Your fab work on this is amazing.
Kim

[Prerunner1982]

great job, can't wait to see the finished product.

[notsolo]

Very Cool...Going to be tough to top Bertha 1... but your closing in fast...Did you have photo's of Bertha 1 with bed painted. I would like to see them. ..Merry Christmas

[cAlvis165]

Thanks for going through the trouble to put this thread back together. Look forward to seeing the bed finished. You truly have amazing skills.

[fourspeedwagon]

Nice work here. Glad I spotted it in the Coe section at the HAMB.
Posted via Mobile Device

[98layinframe]

Wow this thread seriously just made my day! I remember reading thru an old build thread long time ago, and then one day my girl and I were driving up the PA turnpike and I almost broke my neck cause this truck and trailer were sitting at a rest stop we passed. Ofcourse the ole lady thought I was crazy, told her to pull over and back down the exit ramp of the plaza so I could check this thing out in person.... needless to say, I didnt get my way.

I was so disappointed when I couldnt remember where the build thread was and never found the pics again. Definitely wanna see it this time thru!
Posted via Mobile Device

[buggy5872]

Originally Posted by 98layinframe

Wow this thread seriously just made my day! I remember reading thru an old build thread long time ago, and then one day my girl and I were driving up the PA turnpike and I almost broke my neck cause this truck and trailer were sitting at a rest stop we passed. Ofcourse the ole lady thought I was crazy, told her to pull over and back down the exit ramp of the plaza so I could check this thing out in person.... needless to say, I didnt get my way.

I was so disappointed when I couldnt remember where the build thread was and never found the pics again. Definitely wanna see it this time thru!
Posted via Mobile Device

It will be at the world of wheels show in Pittsburgh in about a month....just in case you wanted to come check it out.

[buggy5872]

Now I finished blocking out the rest of the cab and got it in final primer and cut in for assembly.



Then the fun of wiring, interior and dash items to put in.



Here is a word of caution. Do not buy a windshield made in mexico. I fought it for 3 hours and it just would not fit. It ended up shattered on the floor of the garage. I went and dug through my stash of original windshields and found the best one. 20 minutes later it was in with no issues.

[buggy5872]

Here it is assembled and ready to make the trip to my brother's body shop for paint. He thought I was crazy painting it before I even test fitted it on the chassis.

[buggy5872]

After wet sanding until my finger prints were gone, She went into the spray booth for some color. I forgot my camara so I have not pics of it in the booth. While it was drying I headed back to my house to get the chassis. Here it is as it arrived at my brother's place.


could probably use a slightly bigger trailer but it works. Now came the great union. Would it fit????? Thank God my brother has lifts in his garage or it would of been a nightmare to put together


I did not get any pics of the uion but it went pretty smoothly. Had to raise and lower it several times. Frame mounts went right on where they should and a few bolt later and it was a perfect match. The front clip did not line up so I had to take it off the tilt mechanism for the ride home. Here it is safe and sound back at my house.

[Wheelie]

I showed my wife this and she gave the thumbs up to allow me to build one similar only AFTER I finish the one in the garage first Your truck is just freakin awesome.