1957 Chevy: CRUSHED eyebrow repair.

In this video, we tackle a challenging repair on the heavily damaged fender of a 1957 Chevy pickup. The fender has a nasty dent and crease right on the headlight eyebrow, and our initial attempt with heat and hammering proves that a more drastic approach is needed. We walk you through our decision to graft a replacement headlight bucket from a big-truck fender onto the half-ton fender, a process that’s more complicated than it sounds!
Watch as we carefully cut out the damage, align and weld in the patch panel, and navigate the subtle differences in curvature between the two fenders. This isn't just about fixing a dent; it’s about precision metalwork, panel alignment, and a whole lot of hammering and dolly work to get the body lines just right. We’ll show you the critical measurements needed to keep the headlight bucket square, and we'll wrap up by test-fitting the headlight bezel for a final look at the successful repair.
Video Chapters:
00:00 Intro and initial assessment of the damaged fender
01:20 Attempting to straighten the damage with heat and a hammer
03:10 Pre-fitting all body panels and establishing door/fender alignment
06:30 The decision to graft a headlight bucket from a big-truck fender
09:00 Cutting the patch panel from the donor fender
11:30 Welding in the new headlight bucket
15:00 Checking alignment with a level and final bodywork prep
17:45 Test-fitting the headlight bezel for a perfect final fit

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   • DIY Metal Working      • 1957 Chevrolet Pickup      • Плейлист      • SHORT BED 1967 C10 Project      • International Pickup Short Bed Conversion  

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