This truck is completely hand crafted from aluminum but styled to have the general appearance of the classic DIVCO delivery truck. We’ll take a close look at how this project was started.
DIVCO delivery trucks were an American institution. They were built by the Detroit Industrial Vehicle Company from 1926-86. If you were around during that time, it’s likely that you saw milk, bread, and other commodities being delivered to people’s homes in these iconic vehicles.
After the custom chassis for the truck was built, a stout sub-structure was made for the body, based on specially formed aluminum channels and flat aluminum plate.
While there are still some DIVCO trucks around, few of them are in good condition, as most had a hard life.
A complete floor was built to fit on top of the channel subframe. This required lots of bumps and steps to clear the mechanical components.
One individual undertook the project of resurrecting one of these venerable trucks in a hot rod style, but for various reasons the project was never finished. The owner took the project to Saltworks Fab in Sarasota, Florida, with the goal of having the project finished there.
Here a simple template is made from strips of sheetmetal, making a guide for forming the transmission cover.
A thorough inspection of the project revealed so many sub-standard areas that would require revision or replacement that the owner came to realize it really made better sense to start over; Saltworks suggested doing the entire build from aluminum. Aluminum has several advantages over steel: it’s lighter, easier to form, and it doesn’t rust.
This is the cover for the transmission and bellhousing, formed from heavy-gauge aluminum sheetmetal.
Roadster Shop built a stout new chassis for this project, which was considerably modified by Saltworks. It is based on a Generation III Hemi, built by Bouchillon Performance Engineering, with the transmission prepared by Bowler Transmissions. The rear axle was built by Strange Engineering and air suspension is used front and rear, which will allow the truck to rest literally “on the ground” when parked. The wheels were custom made by Curtis Speed.
The kickup in the floor over the rear axle assembly was an intricate fabrication project. Great care was taken to ensure good fit and finish both inside and out. Note the long-travel air suspension unit fitted to the rear axle housing, which will allow the truck to be lowered dramatically when parked.
The body is constructed over a sub-structure made from specially formed aluminum channel, with a contoured floor fitted on top. The framework for the body was made from custom-formed box sections, outlining the window and door openings. With this sub-structure completed, the body skin panels could be started.
All of the structural members for the body had to be custom fabricated to achieve the specific sizes required. TIG welding is used exclusively for this project.
While the sides of the body look flat, they all have a subtle contour, so great care was needed to correct the shape of each panel during the fabrication process. After the body sides had been constructed and positioned on the body, a recessed reveal was made to fit on each side, and then inset into the panels. Custom trim will be made to fit in this reveal, which will go a long way toward giving the truck a contemporary look while paying tribute to the traditional DIVCO styling cues.
Here the structure for the body is largely in place—providing a mounting surface for the sides of the body, doorjambs, and window openings.Special curved box sections were fabricated to join the body sides to the rear structure.The rear panel is being mocked up here. The hinges for the rear doors attach directly to the box sections, providing maximum rigidity.Here most of the interior body panels have been fitted and attached. Note the crisp, tight joints everywhere.A special reveal was formed for the sides of the body. The final placement is being dialed-in here.The reveal has been welded into place, and the long joints are being carefully metalfinished. The red dye on the metal is an aid for finding any low spots, which are meticulously worked up until everything is smooth. The sides of the body look flat, but they have a subtle crown.A special insert was made for the lower rear body panel. A snug recess was formed for mounting the insert.This complicated stepped panel will become part of the ’jamb for the rear doors.A dipped section was formed in the center of this panel.Here the ’jamb is being fitted with the body and the internal structure.The corners of this junction required precise fitting, but you can see that everything is perfectly aligned. With careful welding and metalfinishing, the result will be impeccable.Here the frames for the rear doors have been assembled and partially fitted.At this stage, the outer skin has been attached to the door, and the action of the hinges and latches can be tested.The roof on this truck is enormous and had to be constructed from many separate pieces. Most of the roof is metalfinished here with just a few small areas left to complete.At this stage, the roof panel is completely smoothed and ready for joining to the windshield header panel and the body sides. Next time we’ll look at many more of the intricate details on this dazzling project.
