Sometimes it's hard to come up with a cool part for a car that is iconic like the '57 Chevy. Everyone is so familiar with how it's "supposed" to look that any deviation can backfire. But sometimes a product comes out that does change the look, but in a good way. The product we are talking about in this story is the new one-piece smoothie-style bumper and grille insert from Danchuk. Here is the tweak that Danchuk spent a few years developing. It's a completely smooth one-piece bumper and new grille that once installed really gives the '57 a different look. The redesigned bumper not only features no seams or exposed bolts, it also deletes the bullets from the front end. Since the bullets are removed the grille insert needed to be extended to fill the area usually covered by them. The new grille inserts are offered in either silver or gold.Here is the tweak that Danchuk spent a few years developing. It's a completely smooth one- Steve Brown, general manager of Danchuk, says, "As the demand for hot rod and retro rod parts increases, it helps us to justify large and expensive projects like this one. We spent almost two years between the design, tooling and production of this work of art and we couldn't be happier. We use top quality steel and the best American chrome plating money can buy." The bumper and grille are designed to bolt right onto the car with minor modifications to the bumper brackets. When we got wind the first bumper was fresh out of the chrome shop, we just had to get it on a car to see how it looked. We went over to Danchuk's facility in Santa Ana, California, and had them toss one on the company's red '57 Bel Air that we tested way back in '08 (check out www.superchevy.com for the story). The car is still very clean considering it gets driven daily. Our workers for the install are Pete Adame, 1st article technician, and Lawrence Kelly, design engineer. These two guys had the bumper swapped out in under an hour with no air tools so it should be no problem to do it at home. Here is the oh-so-familiar '57 front end. This car already has the cleaner, one-piece bumper instead of the multi-piece unit found on non-California cars. While not a bad looking factory design at all, there can always be tweaks made to change it up.Here is the oh-so-familiar '57 front end. This car already has the cleaner, one-piece bump Obviously, before we can get the smoothie bumper on, the stock stuff needs to come off. First thing in that process are the bullets, which are Danchuk's chrome versions. On this car they just screw off, which then frees the larger rear piece.Obviously, before we can get the smoothie bumper on, the stock stuff needs to come off. Fi Here is what the bullet area looks like once it's off. Now you can see why Danchuk needed to make a new grille insert to fill the void left when the bullets come off. You can also see the flat area, where the bullet mounts to the bumper, which had to be redesigned in the new bumper.Here is what the bullet area looks like once it's off. Now you can see why Danchuk needed Before loosening any of the bumper bolts, make sure to protect the paint at the fender. The outer section of the bumper is very close to the sheetmetal and when the bolts are loose the bumper will want to rotate and contact the fender.Before loosening any of the bumper bolts, make sure to protect the paint at the fender. Th For this car it's better to remove the bumper from the bumper brackets instead of trying to take off the bumper and brackets as a unit. You will need an 11/16 socket and a short extension to tackle the bumper bolts.For this car it's better to remove the bumper from the bumper brackets instead of trying t You will need to elongate the holes (bracket to frame) on all the bumper brackets so they will slide towards the rear of the car about a 1/2-inch. You can see the difference in this shot between the stock (top) and modified (bottom). This needs to be done because the new smoothie bumper has shaved bumper bolts so the mounting area is in a slightly different position, but we'll show you a picture a little later. After modifying the brackets, put them back on the car but do not tighten the hardware all the way.You will need to elongate the holes (bracket to frame) on all the bumper brackets so they The grille bar is next to be removed and it is held on with 7/16 nuts. Now the grille itself can be unbolted and taken out of the car. This '57 has aftermarket button-head Allen bolts, but stock will most likely be 7/16 heads. The best way to get it out without damage is to pull out on the bottom until it clears the lower valance, then drop it down to free it from the top.Now the grille itself can be unbolted and taken out of the car. This '57 has aftermarket b After all the mounting clips were transferred to the new grille, it was slipped up into place. Once it was all tightened up, the center bar was also reinstalled.After all the mounting clips were transferred to the new grille, it was slipped up into pl Here is a good look at how the new bumper will attach to the brackets. Danchuk welds on these slotted tabs to the back of the bumper and provides a thin-head carriage bolts.Here is a good look at how the new bumper will attach to the brackets. Danchuk welds on th This new mounting tab protrudes back from the bumper and shows why the bumper bracket holes needed to be elongated a bit.This new mounting tab protrudes back from the bumper and shows why the bumper bracket hole There is a proper way to hang this new smoothie bumper so you are not pulling your hair out trying to line up all the carriage bolts.There is a proper way to hang this new smoothie bumper so you are not pulling your hair ou Since the very center mounts are not carriage bolts, these will be installed first. There are nut plates welded to the bumper jack support (the black bracket in Pete's left hand) that will sandwich the tab on the bumper between it and the center bumper brackets once tight. Right now just snug up the hardware so you can still reposition the bumper until you get all the hardware installed.Since the very center mounts are not carriage bolts, these will be installed first. There Now you can slip in all the carriage bolts. Having the bumper brackets loose will help in this step. Once you get them all in, make sure the bumper lines up with the bodyline in the fenders and tighten up all the bolts.Now you can slip in all the carriage bolts. Having the bumper brackets loose will help in Here is the finished product. The new Danchuk Smoothie bumper and grille will set you back $849.90, which is still less than having a custom bumper made from scratch. If you want to make your '57 look different then the rest of them out there, this is definitely something to consider.Here is the finished product. The new Danchuk Smoothie bumper and grille will set you back SOURCES Danchuk 3201 South Standard Avenue Santa Ana CA 92705 800-648-9554 www.danchuk.com By Calin Head Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!
