'57 rear bumper alignment issues

[Bangback]

Hi,

I got by 3 Piece rear bumper set from Danchuk for my '57.

I assembled it all together and it looked great, until I put it on:

http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/35db3f8d.jpg

I played with all afternoon today, had all my bolts loose but couldn't seem to get the alignment right. It was about a half inch too far to the right, and there wasn't enough play.

The bumper and the ends came in a Golden Legion box. Is this brand known to have fit issues?

My original was, although pitted, perfectly aligned and straight as seen here:
http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/trunk.jpg


Any ideas of what to try next?

[angs1957]

Not to be bearer of bad news but depending on the tooling at the time of when your bumper was manufactured that may be as good as you`ll get it.

You can try loosening up the bumper ends and placing washers/spacers to try and make it a better fit, either way you will need to tweak it a little OR send it back :anim_25:

[Bangback]

Not to be bearer of bad news but depending on the tooling at the time of when your bumper was manufactured that may be as good as you`ll get it.

You can try loosening up the bumper ends and placing washers/spacers to try and make it a better fit, either way you will need to tweak it a little OR send it back :anim_25:

The problem is, putting in washers won't help me laterally left or right. The position of that movement is held by the 4 chrome bolts, which are carriage bolts and can't move.

The two center brackets they are attached to attach to the outside of each side of the frame. So I can't adjust it there either.

The only slack I have is between the bumper and the center bracket, which has a little play but not a lot.

The only choices I think I have are:

- drill out the holes on the center brackets so that they are larger
- order a center bracket set and use a bracket for the opposite side. The bracket will be inverted, but will give me an extra inch of room, but I'm going to need a lot of washers to make up for it.
- get my original bumper chromed (maybe I should have done that in the first place?)

[chevman57]

That looks to be about as good as you are going to get that aftermarket bumper to fit.
get my original bumper chromed (maybe I should have done that in the first place?)
That would be my suggestion.
Terry

[mickeywestsr]

Have you talked to the vender about returning the bumper? I'd be burning up the phone lines....:anim_25:
:gba:
bowtie-trifive

[Bangback]

I decided to take my bumper back off and see if I could make it work better.

I am using all the original brackets from the factory.

When they were on the original center bumper, they all lined up in a straight line.

This is how they line up on the Golden Legion bumper from Danchuk:

http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/a89410c8.jpg

http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/b5c1716e.jpg

The right side is further off than the left side. It ends up being about 1/2" to an 1" too far to the right. The four holes on the center piece seem to be off, at least with the original brackets. I'm not sure new brackets would help. Car hasn't been in an accident and everything seems pretty straight.

What I'll try next is swapping the brackets from L to R and R to left. This will probably make me use a whole box of washers to close up the gap on each side, but at least I should now be able to widely reposition my bumper laterally and make it fit right. This is of course, if the overall dimensions of the bumper are correct, which I still need to verify.

[Original Pete]

Not to be bearer of bad news but depending on the tooling at the time of when your bumper was manufactured that may be as good as you`ll get it.

You can try loosening up the bumper ends and placing washers/spacers to try and make it a better fit, either way you will need to tweak it a little OR send it back :anim_25:

:congrats::congrats::congrats: That's why I am a stickler for the original parts, even if they are not perfect. Far too many of these stories are being told these days.:anim_25:

[acardon]

I had the same issue with a repop bumper only much much worse. The end pieces were too wide to fit under the tail lights. I ended up using the repop center section and having some original end pieces rechromed.
If your old one fit and can be chromed, have it rechromed.
http://pic100.picturetrail.com/VOL678/4398712/9300251/291541347.jpg

[Thumper]

I had the same issue with a repop bumper only much much worse. The end pieces were too wide to fit under the tail lights. I ended up using the repop center section and having some original end pieces rechromed.
If your old one fit and can be chromed, have it rechromed.
http://pic100.picturetrail.com/VOL678/4398712/9300251/291541347.jpg
I agree, if you know your stock bumper fits, get it rechromed. It is very common for the straight section to need section cutting to obtain a good corner section fit, even in OEM bumpers.

[scorpiopilot]

I had the same issue with a repop bumper only much much worse. The end pieces were too wide to fit under the tail lights. I ended up using the repop center section and having some original end pieces rechromed.
If your old one fit and can be chromed, have it rechromed.
http://pic100.picturetrail.com/VOL678/4398712/9300251/291541347.jpg

:tu X infinity !

[scorpiopilot]

I agree, if you know your stock bumper fits, get it rechromed. It is very common for the straight section to need section cutting to obtain a good corner section fit, even in OEM bumpers.

Really? sectioning an OEM rear middle bumper because it's too long? I've never heard of or experienced that problem/solution before. Learn something everyday

[Bangback]

Wow, the opening on that end piece really seems off, almost as if they went by a sketch instead of a real engineering drawing to make the part.

I'll have to make measurements of my original end pieces and compare them with my repops. I don't think mine are too far off, if they even are.

I had the same issue with a repop bumper only much much worse. The end pieces were too wide to fit under the tail lights. I ended up using the repop center section and having some original end pieces rechromed.
If your old one fit and can be chromed, have it rechromed.
http://pic100.picturetrail.com/VOL678/4398712/9300251/291541347.jpg

[fiddlerpin]

Bolt your end sections to the original center section and see if it fits better. Looks like the center section is longer on the new one.

[Bangback]

Bolt your end sections to the original center section and see if it fits better. Looks like the center section is longer on the new one.

I think you're right.

After swapping the center bracket positions so they face outward instead of inwards, and using 48 washers as shims and 3-inch bolts instead of 1-inch, I got it centered as best as I could but the bumper ends still stuck out further than the originals on both sides.

The only thing I can deduce at this point is that either:
1. the center piece is slightly too big, or
2. the bumper ends are slightly too large.

This would explain why in my previous pictures the corner brackets for the bumper ends are slightly out of plane from the center brackets by about a half inch on one side to almost an inch on the other.

You would think that since it came as a 3-piece set as one part number the pieces would match and all fit together nicely, but it doesn't. I thought by ordering this set from Danchuk, I'd get something better that might be made in the USA than to order it from other places, but I guess since it doesn't say Made in the USA in the catalog next to the item, it's either made in Taiwan or China, and unfortunately, all the parts seem to be coming from the same manufacturer(s) overseas. I'd gladly pay extra if they were made here in the US, and if they actually fit like the originals.

I'm not sure what I'll do at this point.

[angs1957]

I think you're right.

After swapping the center bracket positions so they face outward instead of inwards, and using 48 washers as shims and 3-inch bolts instead of 1-inch, I got it centered as best as I could but the bumper ends still stuck out further than the originals on both sides.

The only thing I can deduce at this point is that either:
1. the center piece is slightly too big, or
2. the bumper ends are slightly too large.

This would explain why in my previous pictures the corner brackets for the bumper ends are slightly out of plane from the center brackets by about a half inch on one side to almost an inch on the other.

You would think that since it came as a 3-piece set as one part number the pieces would match and all fit together nicely, but it doesn't. I thought by ordering this set from Danchuk, I'd get something better that might be made in the USA than to order it from other places, but I guess since it doesn't say Made in the USA in the catalog next to the item, it's either made in Taiwan or China, and unfortunately, all the parts seem to be coming from the same manufacturer(s) overseas. I'd gladly pay extra if they were made here in the US, and if they actually fit like the originals.

I'm not sure what I'll do at this point.

Danchuk are very approachable, express your concerns and what is needed to get the problem rectified :anim_25:

[jewel57]

Please keep us informed to the outcome, I also have a alignment issue (not so severe) with a new three piece rear bumper from Ecklers.

[Bangback]

I emailed Danchuk Customer Service last night. I haven't heard back from them yet, but I'll post on whatever happens.

Please keep us informed to the outcome, I also have a alignment issue (not so severe) with a new three piece rear bumper from Ecklers.

[Muscleparts]

Gave my buddy some original driver quality bumper parts. Seen them on the car over the weekend, The centering looked good but both ends were turned outward almost exactly the same amount. The center came off my car with series 1 ends and IT DID NOT look this way. He has series 3 ends on that center now and something is not right and this is factory stuff. Does series of ends or manufacturing plant affect alignment. I think I know the answer to this, but has anyone run into this before. So even factory stuff can have issues, but not as bad as what im seeing from this Danchuk piece.

[Bangback]

Gave my buddy some original driver quality bumper parts. Seen them on the car over the weekend, The centering looked good but both ends were turned outward almost exactly the same amount. The center came off my car with series 1 ends and IT DID NOT look this way. He has series 3 ends on that center now and something is not right and this is factory stuff. Does series of ends or manufacturing plant affect alignment. I think I know the answer to this, but has anyone run into this before. So even factory stuff can have issues, but not as bad as what im seeing from this Danchuk piece.

I did some more research. In a lot of pictures out there on the internet, it's hard to tell if it's original stock, original re-chromed, or a completely new repop. There are a lot of variances out there, with positioning, and spacing between the taillights. However, in one of the restoration guides that I have, there are a bunch of photos from the GM Proving Grounds. They are pictures of a straight shot of the back of the car, of the different models that were out for '57, in black and white.

In each of the different models, you could see some slight variances in taillight/bumper end positioning. On some, you could see that the bumpers were not aligned the same as on other cars. Some were slightly to the left or just to the right. I don't know if the variance is a result from testing done at the Proving Grounds, or if it was the way it rolled off the line.

Presumably, I believe that there were some variances on cars coming out of the factory as far as the positioning of the bumper and how it looks in relation to the taillight. But they weren't as noticeable as some of the alignment issues I've been having.

[Scott Phillips]

I had planned to purchase a complete rear bumper from Danchuk but after seeing the issues you're having I think I'll take another route. Did you purchase a bumper with or without ridges? My car came with one ridged end and one smooth. Does ridged or smooth ends make a difference on the fit?

[Bangback]

I had planned to purchase a complete rear bumper from Danchuk but after seeing the issues you're having I think I'll take another route. Did you purchase a bumper with or without ridges? My car came with one ridged end and one smooth. Does ridged or smooth ends make a difference on the fit?

What I purchased was item #10447 from their website.

Here is the exact description of this part, which I just copied from their website:

----

http://www.danchuk.com/ItemForm.aspx?Search=10447&Item=10447

http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/10447.jpg

Caption reads:
Once again we couldn't leave well enough alone. These bumpers have always been pretty nice, but we just had to make our own and bring the game up a notch. We use quality steel for these and then give them the most beautiful American triple plate chrome plating that money can buy. Danchuk # 10447 will work on any model 1957 classic Chevy hardtop, sedan or convertible. OS2 shipping required. Check for availability.
----


So it sounds from the description that since they "make their own", that they'd be coming from California, right? No, mine came from a Golden Legion box (actually 2 boxes, one for the center piece and one for the bumper ends), which I presume are made in Taiwan. I think the description is very misleading, because it seems to imply that since Danchuk manufactures parts, and that they refer to it as "make our own" that they are actually made in the USA. But if they fit properly, then I wouldn't care as much if they were made elsewhere either.

http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/1b828359.jpg

This is the box it came in, with the Danchuk part number 10447 label and all.

By ridge, do you mean the ridge on the side, or the ridge on the top of the bumper ends (like Series 1)? Mine were both smooth on top but had ridges on the sides, which I guess make them series 2? I didn't have an option to select a ridge or not.

I haven't played with mixing and matching the original factory pieces with the repops yet, so I'm not sure if one "fits" better than the other.

I haven't heard back from Danchuk's Customer Service yet from my email to them.

[Scott Phillips]

Yea, I've found that several items I purchase from my suppliers comes from places that I didn't expect. Going in to my build I had a plan to use only "Made in America" but now like you I just want what fits. I was talking about the ridge on top of the bumper ends. My rear bumper fit pretty good (needs rechrome) but because one was with and one without the ridge I was going to purchase new so everything would match.

[Bangback]

Yea, I've found that several items I purchase from my suppliers comes from places that I didn't expect. Going in to my build I had a plan to use only "Made in America" but now like you I just want what fits. I was talking about the ridge on top of the bumper ends. My rear bumper fit pretty good (needs rechrome) but because one was with and one without the ridge I was going to purchase new so everything would match.

I believe my originals did not have the top ridge and are smooth. My date of manufacture is about the last week of November 1956 in Flint, based upon my VIN. Perhaps they changed from Series 1 to Series 2 before the end of 1956?

I may try to play with mine a bit more, perhaps this weekend. I'm thinking now if I possibly place some shims on the taillight housings, I could try to change their angle and make them more in line with the bumper end, but this would open up a gap between the fin and the taillight housing.

[hpnelson001]

I had the same issue with a repop bumper only much much worse. The end pieces were too wide to fit under the tail lights. I ended up using the repop center section and having some original end pieces rechromed.
If your old one fit and can be chromed, have it rechromed.
http://pic100.picturetrail.com/VOL678/4398712/9300251/291541347.jpg

That's exactly what I did...I ordered a repop center section and used all the brackets off the orginal bumper and got rechromed ends for the mating of the rear bumper to the body. I guess it worked. Are you sure you have the brackets on the correct side? I think mine fit on the outside of the frame on both sides...just wondering. :anim_25:

[hpnelson001]

Hi,

I got by 3 Piece rear bumper set from Danchuk for my '57.

I assembled it all together and it looked great, until I put it on:

http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/35db3f8d.jpg

I played with all afternoon today, had all my bolts loose but couldn't seem to get the alignment right. It was about a half inch too far to the right, and there wasn't enough play.

The bumper and the ends came in a Golden Legion box. Is this brand known to have fit issues?

My original was, although pitted, perfectly aligned and straight as seen here:
http://i53.photobucket.com/albums/g57/bangback/1957%20Bel%20Air%20Sedan/trunk.jpg


Any ideas of what to try next?

Maybe I"m just seeing things in this photo, but the bumper end seems to be twisted outward and to the right, or about pointing at 5:00 o'clock position. could it be the middle bumper has a mounting flange that can be realigned by a well placed hammer, or prybar. It looks like it's on crooked, not too long, but on at an angle...maybe?

[Bangback]

Maybe I"m just seeing things in this photo, but the bumper end seems to be twisted outward and to the right, or about pointing at 5:00 o'clock position. could it be the middle bumper has a mounting flange that can be realigned by a well placed hammer, or prybar. It looks like it's on crooked, not too long, but on at an angle...maybe?

Yeah, that was the best I could get it, at the time, which is why I went back, swapped bracket positions and used washers to get it better positioned. I thought of getting new center brackets, even though mine weren't bent, but figured that it wouldn't matter much because there is no play left/right because of the carriage bolts through the bumper.

The bumper end brackets are correct. They are mounted as my originals were. I tried them on the other side and and in alternate positions, but it doesn't even come close to fitting that way.

I also tried to get the bumper ends to be more flush with the top surface of the center bumper. That's the best that it got. I wonder if there's a way to add shims to change the angle of the bumper ends from the center piece?

I think what I need to do is to just take everything apart again, and measure everything, old and new, and see where the differences are. This way I can zero in on where the problem is and go from there.

[TheHotrodHandyman]

This is a common issue with the repro 57 rear bumpers. They are too wide for the car. You need to measure each of your original pieces and compare to the new pieces. No amount of adjusting and playing with brackets is going to make the bumper any narrower.

[Bangback]

It's been about a week and I never got a response from Danchuk from my e-mail to their customer service department about my bumper issues.

With a little bit more elbow grease last weekend, I aligned it as best as I could. The centerline of each taillight down to the bumper end is slightly off, as either the center repop piece is too large, or the bumper ends are too large, but I've decided to live with it for now. The chrome finish itself is quite good, and it looks better than what I had before, even if the alignment is slightly off.

Still, I expected the fit to be better for something coming from Danchuk.

I'm saving my original pieces though, for possible re-chroming sometime in the future, perhaps when the repops begin to rust.