Journey with Big Blue
1990 Chevrolet C-1500 Cheyenne Restoration
The Origin Story
The Journey Begins
Big Blue – The Origin Story
First of all, let's introduce you to Big Blue. Big Blue, is a 1990 Chevrolet C-1500 pickup truck, equipped with a 305 cubic inch V-8 engine, standard cab, 8’ pick-up bed, and was painted “medium sapphire blue metallic” – hence the name Big Blue. While I often claim I bought it new, technically, that's not entirely accurate, but I'll explain that in a moment.
In the spring of 1990, shortly after Big Blue rolled off the assembly line in Pontiac, Michigan, I landed a job as a Public Affairs Specialist at NASA’s Goddard Spaceflight Center in Greenbelt, Maryland. Naturally, this meant relocating my family from Rhode Island to somewhere within commuting distance of the Space Center.​
Major Wayne Morse waits for a lift in Big Blue to Washington, DC where we ran in the Georgetown 10K.
Four-year-old daughter Victoria wanted her Easter picture taken in Dad’s beautiful blue truck. Easter 1992.
We settled in Severn, Maryland, a suburb closer to the NSA (National Security Agency) than the NASA facility in Greenbelt. This quirky twist of fate occurred when our relocation expert, a retired Army Colonel turned realtor named James McSlarrow, misheard my request to be "near NASA" as "near NSA". Over the years, we kept in touch with Jim and got to know his son Kyle McSlarrow, who later ran for US Congress in 1992 and 1994 – with outcomes similar to my own congressional campaign in later years.
Life in Severn suited us well, but one thing became abundantly clear – in the sweltering heat and humidity of the DC area, car air conditioning is not a luxury but a necessity.
My wife Suzie-Q was fortunate, driving a fairly new Toyota Camry with a robust A/C system. Meanwhile, I was driving a 1986 Ford F-150 from E.P. Fournier Ford in East Providence. Retrofitting it with A/C was impractical.
Being a loyal Ford fan, I headed to Academy Ford in Laurel, Maryland, where I purchased a Ford Ranger with only two options: AM/FM Cassette radio and air conditioning, complete with a manual transmission.
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In Rhode Island, driving a manual transmission was no big deal, but navigating the Washington Beltway was a different story – a constant cycle of shifting gears and stopping. I joked that driving a manual in DC traffic would give me the physique of a fiddler crab – a beefed-up right arm from shifting and a puny left arm.
Yes, it did occasionally snow in the DC area. This one was big, even by New England standards. We did manage to get Big Blue out of the snowdrifts after some effort.
But the Ranger had its limitations – a small cab and limited cargo capacity. I needed a full-size pickup. My default choice was the Ford F-150, but I wasn't keen on the redesign in 1987. So, I turned my attention to Chevrolet and GMC pickups. Chevrolet offered three trim levels, with the Silverado at the top end, which I felt was overly luxurious. At the bottom was the W/T (Work Truck), only available with a Vortec V-6 engine. I needed the power and reliability of a V-8 for household chores and commuting in DC traffic. The middle-ground Cheyenne model, with its rubber floors, vinyl seats, and crank windows, seemed just right. Plus, I could add air conditioning.After visiting numerous Chevy dealerships without success, I stumbled upon an ad in the Baltimore Sun for a Cheyenne with under 10,000 miles. Custom-ordered by a GM employee who worked at the GM mini-van plant in Dundalk, the truck was located in South Baltimore. With a trip to the NASA credit union for a certified check of $9,000, I sealed the deal and my enduring attachment to Big Blue (named by my 4-year-old daughter Victoria) was forged.
The Early Years
The Journey Continues
One of the perks of working for NASA is hanging out on the flight deck of the Space Shuttle simulator. (notice how everything is turned off, so I couldn’t break anything).
Life with Big Blue was a lot of fun. My first upgrade for the truck was a locking gas cap. With Big Blue boasting a fuel capacity of 30 gallons, I wasn’t keen on risking any gas theft.
Big Blue became my daily driver, shuttling me first to NASA Goddard in Greenbelt. Later, a transfer to NASA Headquarters meant navigating the perilous daily commute to 400 Maryland Ave, near L’Enfant Plaza, and eventually to 300 E Street SW, where a spacious underground garage awaited.
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​Our travels often took us on at least two road trips per year to Rhode Island to visit family. Come August, we’d hook up a small pop-up trailer for Suzie-Q’s annual family camping trip, typically in upstate New York or Western Massachusetts. During the holidays, Big Blue dutifully transported presents and luggage under its fiberglass cap. The roomy cab easily accommodated our daughter Tori’s car seat.
Like any vehicle, Big Blue had its share of minor troubles during these early years. At around 16,000 miles, the truck refused to start one morning due to a faulty ignition module. Its replacement lasted over 225,000 miles, finally giving out after the John Loughlin Show in the WPRO parking lot in 2019.
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Then there was the infamous Perrier incident. On a return trip from Rhode Island to Maryland, I noticed a worrying spike in temperature. Unbeknownst to me at the time, a hose leading to the heater core in the engine compartment had sprung a leak. We pulled over and resorted to adding bottled water we had on hand. About a mile shy of the Ft. McHenry tunnel, Big Blue began overheating again. With nothing but two bottles of Perrier left, we poured them into the radiator and managed to limp home, with repairs promptly carried out the following day.
Suzie-Q enjoys some fresh picked corn-on-the-cob during a family camping trip, while Big Blue protectively looks on.
Another memorable tale from those early years involved a meeting at 500 North Capitol St. The building housed CNN News Source, a syndication outlet for CNN that needed some shuttle footage we possessed. Interestingly, it also housed the IRS enforcement division – a detail that becomes significant shortly. With rain pouring down, I opted to drive Big Blue to the meeting, banking on the convenience of moving between underground garages.
NASA Headquarters, now named for "Hidden Figure" Mary Jackson, across town from CNN Washington.
The underground garage at IRS/CNN proved to be a challenge, with its tight parking spaces. The only spot I found was so snug that I had to exit through the passenger door.
Upon returning to Big Blue after the meeting, I found a lengthy handwritten note under my wiper scolding me for parking too close. It repeatedly referenced someone named “Roger Henderson” and warned, “we know who you are.” As it turned out, I had inadvertently hung my Maryland National Guard security pass on my rearview mirror, prominently displaying the name "Colonel Roger Henderson – Security Officer."
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I never did inquire if Col. Henderson ever faced an unexpected IRS audit.
Then there was the time I parked in the Pentagon Press parking lot for another meeting and inadvertently left my lights on. Upon returning, I found a note from NBC News Pentagon correspondent Ed Rabel on my seat, informing me that he had turned off my lights to prevent draining the battery.
Big Blue even got a very small role in a TV show pilot. The pilot was called Fun House, with Comedian / Plumber Ed DelGrande. While the pilot never took off, Ed went on to find fame with the Home and Garden and DIY Networks on cable TV. He even had his own show, Ed The Plumber. The deal was, if my truck was in the show, I got to be in the show too. You'll see my non speaking role at the end of the clip.
Jed Clampett’s Truck
In the spring of 2000, around the 10th birthday of Big Blue, I was offered a job in Providence. This was a fantastic opportunity to return to Rhode Island and raise our family where Sue and I had grown up.
When we returned to Rhode Island to begin house hunting, we decided to approach the Ocean State with fresh eyes, disregarding where friends and family lived. We wanted a more rural setting and a small town, as opposed to the suburban Maryland environment where we had spent the last decade. We began exploring every corner of our beautiful state.
After a trip to the Tiverton/Little Compton peninsula, we purchased four acres of land in Southern Tiverton, right on the Little Compton border, and began the process of building our new home. Big Blue proved invaluable during this time, with numerous trips to lumber yards, appliance dealers, and more.
The new job was as a Business Development Executive for a start-up software/media company. Business Development Executive is a fancy term for salesman; it looks better on business cards. I settled into the role well, occasionally leading the company in sales, all while still driving Big Blue as my daily driver.
121 South Main St. Providence, home to Heminway's restaurant on the first floor, and Context Media on the second floor. Locally, this building is referred to as the "Rubik's Cube".
By now, Big Blue was mostly a mottled mixture of blue and gray. A great deal of its once lustrous “medium sapphire blue metallic” paint had chipped or flaked off. Since I typically met with prospective clients at their place of business, I didn’t need a ride to impress. That is, until the director of sales, Mike Nawrocki, decided to accompany me to close a major defense contractor on the Boston beltway. On this occasion, he insisted I drive, so off we went in Big Blue.
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The meeting was extremely successful, and we closed a $1.2 million deal, the largest since the company started. On our way back to the office to celebrate, Nawrocki exclaimed, “I can’t believe you took me to close a huge deal in Jed Clampett’s freakin’ truck!!!". With my sales commission in hand, I decided to relegate Big Blue to weekends and household chores and bought a proper car for my daily commute.
Paint was coming off Big Blue in sheets at this point. A flaw in the primer was the likely culprit. Still ran and drove great, however.
Big Blue would be sidelined until another significant event arose.
Jerry's Bumpers
On the job at Ft. Bragg, Fayetteville, North Carolina.
In early 2003, my Army Reserve unit called me to active duty. My assignment was to lead a group of trainers to prepare Reservists and National Guard members for the 2004 Iraq invasion, stationed at Ft. Bragg in North Carolina. Naturally, I brought my trusty truck with me to Ft. Bragg, and she became my daily driver once more.
Big Blue came in very handy. While she wasn’t much to look at, she was exceptionally dependable and reliable for getting me, and assorted gear, to and from Ft. Bragg. Because the mobilization filled all the accommodations at Ft. Bragg, my crew and I stayed in hotels in Fayetteville, North Carolina, that the Army had under contract.
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One evening, during a huge downpour, I was making my way to the hotel. While stopped for a red light, I was rear-ended by a car that had, itself, been rear-ended. The collision damaged the step bumper, but fortunately, no one was hurt.
After retrieving a copy of the accident report, I filed a claim with my insurance company. This was followed by a knock at my hotel room door from an insurance adjuster who looked like he came out of central casting. He had to weigh more than 300 lbs., and his sweat-soaked seersucker suit and porkpie hat screamed “old South”.
“I’m gonna write you a big ole check, Colonel, for $1,200 dollar.” (Note the singular instead of the plural.) “If I were you, I’d go to Jeeeerry’s Bumpers in town, buy a new one for $300, and put the rest right in yo pocket,” he said.
After a trip to Jerry’s Bumpers and a visit to the self-service garage on post to install the new bumper, Big Blue was 100% mission capable once again.
Active duty ended in 2004, and Big Blue and I came home, none the worse for wear. Big Blue was relegated to weekend status once again and would remain that way for the next six-years. Meanwhile, the truck continued to lose more and more of its paint and looked very much like Jed Clampett’s truck…. until campaign 2010.
Jerry's Bumpers, 121 Drake Street, Fayetteville, NC
Campaign 2010 - US Congress
Announcing my run for US Congress in Rhode Island's First Congressional district from the steps of the former Lincoln Community School where I attended 3rd through 6th grade. Former Governor Lincoln Almond (right) was the key note speaker.
By the summer of 2009, Big Blue was 19 years old, and I was serving in the Rhode Island General Assembly. Big Blue was primarily a weekend truck, mostly helping with household chores. That same year, I made the decision to run against Patrick Kennedy for the U.S. House in Rhode Island’s First Congressional District.
This decision meant a great deal of travel, crisscrossing the district in search of support, and the never-ending quest for fundraising, a necessary evil in the reality of today’s politics.
In January of 2010, a surprising thing happened in the political world right next door in Massachusetts. Scott Brown, a relatively unknown State Senator, was elected to fill out the remainder of Senator Ted Kennedy’s Senate term. An icon of this race was that he traversed Massachusetts in search of votes in his pickup truck. In fact, his pickup truck campaign became legendary.
Unfortunately, Big Blue was nowhere near up to the task of being a legendary campaign truck. Most of its once-lustrous medium sapphire blue metallic paint had by now flaked off, leaving a mottled mixture of gray primer and surface rust. At the time, I was driving a Ford sedan, which was okay on gas, comfortable, and reliable as I made the campaign rounds.
Actor Tom Kemp, who played the Chief of Police in the CBS pilot Waterfront with my trusty Ford Crown Victoria. My Ford looked so much like a police car I would rent it out to movie companies - paid for itself over time.
With former Massachusetts Senator Scott Brown at Campaign Headquarters in East Providence, RI.
In February of 2010, Patrick Kennedy dropped out of the House race, leaving a void filled by several eager Democrats looking to move up. Suddenly, my long-shot campaign started to look viable, and I was receiving some attention from Washington.
Part of running for statewide office or, in this case, a congressional district, means a ton of meetings and appearances. By summer, I was putting in 14-hour days, constantly traveling from event to event in my Ford. That left little time for the more mundane tasks of daily life, including, unfortunately, routine car maintenance.
It was about 10:00 PM on a warm July night when all the lack of maintenance caught up with me. I was leaving a fundraiser in Newport, headed home in my Ford, when I ran the car out of oil and destroyed the engine.
This left me with no alternative but to put Big Blue back in service. My first stop with Big Blue was an evening fundraiser in Warren, RI.
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Enter Ken Botelho, owner of Ken’s Autobody in Tiverton. I had gotten to know Ken over the years, as my wife and daughters had gotten into the usual fender benders from time to time. Ken and his sons run the autobody shop, working six days a week. A chance encounter with Ken while I was driving Big Blue led to its first restoration.
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At a campaign fundraiser at an upscale community in Warren, RI, Campaign Manager Cara Cromwell was so appalled at what I was driving she insisted on taking this picture. "No-one would believe what you're actually driving".
​“John, I understand the whole ‘Man of the People’ thing with your pickup truck, but honestly, you look more like an unsuccessful plumber than a future Congressman driving this ‘thing!’” said Ken. “Tell you what, drop off the truck at my shop, give me a couple of weeks, and let me see what I can do.”
2010 Restoration
A badly rusted cab corner removed, still more rust to be ground out. Both cab corners would be replaced.
Big Blue's tailgate, stripping off the factory paint and defective primer.
Work begins outside on the cab with the new cab corners welded in.
Meanwhile, inside Ken's Autobody, the bed is being stripped and repaired.
Another view of the truck bed being faired with body filler to cover 20 years of scrapes and dings.
This is what Big Blue looked like when she arrived at Ken's - can you say "basket case?"
In the paint booth, the first of many coats of paint"medium sapphire blue metallic" being sprayed over new primer.
In August of 2010, I picked up Big Blue at Ken’s. He had replaced rusted-out cab corners and sanded the entire truck down to the bare metal. He primed and repainted Big Blue to the point that it really looked like new.
I was driving a downright respectable truck again, which was even featured, in cartoon form, on the cover of the Providence Phoenix. With a couple of magnetic campaign signs on the doors, it became a great campaign vehicle.
Outside campaign headquarters on Warren Ave in East Providence, magnetic signs added, ready to hit the campaign trail.
Even Massachusetts Senator Scott Brown was impressed and posed with me and Big Blue at a campaign fundraiser on the East Side of Providence.
The HQ sign outside what was the original home of Papa Sam's pizza on Warren Ave.
The traditional "honk and wave." This one was in Portsmouth, RI along with Dr. Chris Ottiano's State Senate campaign.
Youngest daughter Carrie Loughlin who spent her summer with me on the campaign trail. I told her, "this summer you get to go to Politics Camp."
Angry John! Don't remember what the heck I was so mad about - probably because I had to wear the same tie and blazer the whole campaign!
Met a ton of folks across the district during the campaign. These lovely ladies were probably upset I interrupted Bingo. Oh well, there's 3 votes I probably didn't get!
Prepping for a press conference with a haircut WAY overdue as Ian Donnis adjusts the microphone.
I was thrilled and honored to have the support of then Governor Don Carcieri. L - R, my lovely bride Suzie-Q, Me (in the same tie and blazer), Governor Donald Carcieri and his lovely bride Susan Carcieri,
With the Mom's. L- R, Mother-In-Law Dorothy Brush, Me, Mom, Elsa Loughlin and Senator Brown.
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Live from New York! No, not Saturday Night Live, but my appearance on Fox's Sean Hannity Show. I would have included a link to the appearance but those rats at Fox removed all their older clips from YouTube.
Trip to the Southern Border
After landing in Cochise County, Arizona with Mexico directly behind us, we paused for a picture. The helicopter trip was so I could see for myself conditions on the then porous border. L-R Pinal County Deputy Sheriff Rod Rothrock, Cochise County Deputy Sheriff Mark J. Daniels, Pinal County Sheriff Paul Babeu, Me, Cochise County Sheriff Larry Dever.
Prior to departure from Casa Grande, Arizona, in our trusty Robinson R-44 Raven are, L-R Sheriff Babeu, eldest daughter and trip photographer Victoria Loughlin and Deputy Rothrock.
Quick side note, Sheriff Dever and former RIPTA Head and Warwick Mayor Scott Avedisian bear a striking resemblance to each other. In fact, I can't ever remember seeing both of them together at the same time...
Left, The Providence Phoenix cover story. If you would like to actually read the story, drop me an e-mail john@johnloughlinri.com and I can send you the PDF.
If only the campaign had turned out as well as Big Blue. I lost the November election by a narrow margin and began planning for what was next. To foreshadow a bit, it would involve a trip to the Middle East and the beginning of the WPRO chapter.
The WPRO Years - Still Going Strong!
The WPRO logo, when I started in 2013, left, and the WPRO logo today
The WPRO Radio debate during Campaign 2010, as Campaign Manager Cara Cromwell, looks on. This debate would prove more consequential than I even knew!
I often talked about Big Blue during my time behind the mic at WPRO, but the WPRO family is also deeply intertwined with the truck’s history.
I started at WPRO doing fill-in appearances, but it wasn’t until I ran for U.S. Congress in 2010 that I caught the attention of the station’s management. During my ill-fated Congressional campaign, my opponent, David Cicilline, and I took part in three televised debates and two radio debates. After the WPRO radio debate, the Program Director, Paul Giamarco, pulled me aside and said, “If this whole Congress thing doesn’t work out, have you ever thought about doing radio?” I politely replied that the “whole Congress thing was going to work out,” and thanked him for his interest.
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In November 2010, however, the voters rejected my bid to represent them in Congress, and for the first time in my life, I felt rudderless. It was then that I received an unexpected email from the U.S. Army Reserve.
The message explained that the U.S. government had provided surplus Hueys, Cobras, and Kiowa helicopters to the Iraqi Army, which, like me, had been retired from the Army’s inventory. Some genius at the Pentagon thought, “Why not bring back a group of retired Huey pilots to train the Iraqis?”
At the time, I was grateful for the offer, having no prospects after the election, and quickly responded, “I’m ready to go.” After attending "re-greening" training at Fort Jackson, South Carolina, I was off to Iraq.
The experience turned out to be wonderful. Yes, we were frequently shot at, and mortars and rockets often whizzed past us, but we also had the chance to travel extensively throughout Iraq and meet Iraqis who, like me, share a love for flying.
It's amazing what a good Army decorator can do with simple sandbags. Elegant, yet practical.
I returned from Iraq just in time for Christmas 2011 and began what the Army calls “terminal leave”—a somewhat morbid term for someone returning from a war zone. In reality, it simply meant using up leave I had earned but couldn’t take due to, well, a war.
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During my leave, I called Paul Giamarco and reminded him of our hallway conversation. I asked if he was heavily medicated at the time or if he was serious about offering me a shot at radio.
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To my surprise, he said, “Sure, come on in and do some fill-in work. If we like what we hear, we’ll give you a show.” And just like that, The John Loughlin Show was born.
Above: How'd you like to see this coming through the chow line? "No thanks, Sir, not that hungry." Thanksgiving 2011 at FOB Union III, Iraq. An Army tradition I love where the more senior officers serve the junior officers and enlisted Thanksgiving dinner.
Right: Lieutenant Colonel Loughlin reporting for on-air duty, with my favorite Stooge, Larry Fine as a mic flag. I do my show standing, helps me think, some say it's because of where my brains are located.
I often spoke about Big Blue on air, and the truck quickly became a bit of a running theme on the show, much like “Loughlin Marina.”
Traffic maven Robin Murphy told me about a Chevy-sponsored registry called Chevy Truck Legends. I signed up, and my experience with the program has been very positive. Big Blue was inducted into the 300,000-mile club, and each year, they send me a thoughtful Christmas gift—one year, a Chevy Truck Legends hat; another year, a cool tape measure and an oversized golf umbrella.
During a break on my Saturday show, Robin pointed out a substantial puddle of oil under Big Blue—the rear main seal had failed. A thousand dollars later, it was repaired.
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I probably talk too much about Big Blue, but that Chevy pickup quickly became a central part of The John Loughlin Show.
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Once, while filling in for Matt Allen, I learned his producer, “Maverick,” had a collector car—a mid-80’s Chevy Monte Carlo.
My lovely bride Suzie-Q poses with Big Blue at yet another car show.
John Loughlin Show Producer, Radio's Krystle Adams, left and right. In the words of the Moody Blues, "you decide which is real, and which is an illusion."
WPRO Producer "Maverick" and me at a charity car show in Woonsocket showing off our rides.
Another frequent guest on my show was “Professor” David Ise, the owner of a 1966 T-Bird and a director of the Leadfoot Car Club. During one appearance, he wanted to promote a fundraising car show his club was organizing in Woonsocket. I agreed to promote it, but only if I could exhibit Big Blue and Maverick could bring his Monte Carlo—oddly, he agreed to my terms.
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It was at that car show that I met, in person, longtime WPRO listener and contributor “Charles from the Bunker.” I was extremely happy to meet him. He was an odd duck, but with a truly golden heart. Sadly, we lost Charles a few years ago, and the world is a grayer place without him.
The Professor, David Ise in the WPRO studios.
Lets Take This Show on the Road!
Left, at the Rhythm and Roots Festival, with then Program Director Neil Larrimore, and right at Cardi's Furniture and Mattresses L - R Neil, Me, State Director of Veteran Services Kasim Yarn, Operation Stand Down's, Dee D'Quatro and Peter Cardi.
"I feel, feel, feel, like the luckiest man, man, man on the face of the Earth" WPRO night at the old McCoy Stadium
Being yelled at by a bronze statue of actor Frank Sutton who played Sergeant Carter in the hit TV show, Gomer Pyle.
With my favorite Channel 10 News Anchor, (Sorry Gene) Patrice Wood at the Quonset Air Show.
Each year, I send out a goofy Christmas card to the John Loughlin Show advertisers thanking them for their support the previous year.
2023-2025 Restoration: Bringing Big Blue Back to Life
New variable rate coil springs, cleaned and painted ready for a risky installation.
Sometimes, a massive project begins with a small clue. As the new year rolled in, a faint rattle from Big Blue’s front end caught my attention. It was a subtle sign, but one I couldn’t ignore.
By 2023, the 2010 restoration of my beloved truck was showing its age. Rust had crept in, forming what I call "eyebrow rust" above all four wheel wells. Small patches had also begun to eat through the front fenders and the truck bed, signaling it was time for some serious TLC.
The rattle turned out to be a rusted-out link connecting the front sway bar to the lower control arm. A closer inspection revealed heavy corrosion on all four upper and lower control arms, the front coil springs, and the shock absorbers. It was clear: the front end needed a complete rebuild. This wasn’t a small job. Replacing ball joints, tie rods, and other components is a complex task, and handling truck coil springs can be downright dangerous. If a spring compressor fails under the immense pressure of installation, it can cause serious injury.
Determined to do it right, I ordered a full set of replacement parts: new upper and lower control arms with pre-installed ball joints, variable-rate coil springs, sway bar links, tie rods, a control arm, a pitman arm, and high-performance Bilstein shocks. Quality matters when you’re rebuilding a beast like Big Blue.
Before installation, I prepped the parts with a fresh coat of paint to ensure they’d withstand the elements. For the heavy lifting, I turned to a trusted expert: Gary Lamoth, owner of Uncle Henry’s Motors in Tiverton. Gary’s a master mechanic who’s worked on every car in our family, from routine oil changes to complex brake jobs, always delivering top-notch results.
I dropped off Big Blue and my box of freshly painted parts at Gary’s shop. He later shared his ingenious approach to installing the coil springs. Instead of using a traditional spring compressor, Gary relies on the pressure of his lift and a come-along to position the springs, letting the truck’s own weight compress them into place. It’s a testament to his skill and experience.
With the new front end installed, I took Big Blue to a local shop for a precision alignment. The results were incredible—the front end felt rock-solid, tighter than ever. But that tightness revealed another issue: wear in the steering box. Not one to cut corners, I ordered a Red Head steering box, a new Borgeson steering shaft, and a replacement rag joint to complete the overhaul.
The final result? Big Blue handles like it just rolled off the showroom floor. The steering is crisp, the ride is smooth, and the truck feels rejuvenated. This restoration wasn’t just about fixing a rattle—it was about preserving the soul of a classic. Stay tuned for more updates as we continue to keep Big Blue roaring for years to come.
2023-2024: The Restoration Continues – Good Bones?
With the front end rebuild complete, it was time to dive into the full restoration of Big Blue. But a nagging question loomed: were the truck’s bones strong enough to justify the effort?
Big Blue spent its share of time exposed to the New England weather, not on the roads however, just parked outside.
New England winters are brutal on vehicles, and I’d heard horror stories about frame rust. Roger Lebreau, a talented local welder, shared a cautionary tale about a young man who bought a 2012 Silverado—22 years younger than Big Blue—only to discover its frame was rusted beyond repair just a few years later. Financing a truck only to lose it to rust is a nightmare no enthusiast wants to face. Given the corrosion I’d uncovered during the front end rebuild, I couldn’t help but wonder: had Big Blue’s frame suffered a similar fate?
I bought Big Blue in Maryland, where it spent its first decade spared from the harsh road chemicals that plague Rhode Island winters. Except for a brief stint during my Context Media years, Big Blue wasn’t driven much in winter. With two-wheel drive and little weight over the rear axle, it’s no match for snowy Rhode Island roads, so it spent most winters parked. That lack of winter traction might just have been Big Blue’s saving grace.
Armed with my phone’s camera, I slid under the truck to inspect the frame. Surface corrosion was evident, but to my untrained eye, the frame looked solid. To get a clearer picture, I removed the truck bed in the fall of 2023. The bed itself was a lost cause—riddled with rust and far beyond practical repair. It had to go.
A first look at the frame of Big Blue, spending quality time under my truck armed with my i-phone camera. Looked good to me, but what do I know?
A view of the passenger side of the original truck bed, heavy corrosion.
One of the mounting points of the old bed, probably weeks or months away from total failure.
A lucky find on Facebook led me to Southern Truck Beds (ironically, based in New Hampshire). They had a used bed from a Georgia junkyard in great condition. I snapped it up and got to work rust-proofing it. After thoroughly cleaning the underside, I sanded it down, applied two coats of Rust-Oleum zinc-chromate primer, and finished with two coats of gloss black Rust-Oleum. The result was a bed ready to stand up to the elements.
The "new" truck bed arrives from Southern Truck Beds in New Hampshire - Before...
And after, two coats zinc chromate and two coats gloss Rust-Oleum.
Next, I turned to the frame. I enlisted Mike Donovan, a local sandblasting expert, to strip away the rust. When I picked up Big Blue, Mike delivered fantastic news: the frame was in outstanding, near-new condition. With the bare metal exposed, I applied two coats of Rust Bullet, a heavy-duty rust inhibitor, followed by two coats of gloss black Rust-Oleum for extra protection.
Above, frame, fresh from the sandblaster, tucked away in the garage for two coats of Rust Bullet and two coats of gloss black Rust-Oleum. Right, painted and ready for the "new" bed. You can see the springs are masked off. That was to allow for a pun. I painted the springs silver, because I bought the truck in Maryland. Get it? Silver Springs?
Working on the truck in my garage after hours was a labor of love—a perfect way to spend cold winter evenings when Big Blue was sidelined anyway.
With the frame rust-proofed and gleaming, I installed the “new” truck bed in the spring of 2024. Big Blue wasn’t much to look at yet, but I knew I had a rock-solid foundation to build on.
"New" truck bed installed and ready for the next steps in the restoration.
The Heart of the Beast: Rebuilding Big Blue’s Engine
With the frame and body of Big Blue well on their way to restoration, it was time to breathe new life into the heart of the beast—the engine.
They worked their magic—cleaning, replacing bulbs, and reviving all the gauges. Now, with a fully functional gauge cluster back in place, I could accurately track mileage, and the working trip odometer was a nice bonus.
Each time I fueled up Big Blue, I used the trip odometer to calculate gas mileage. The numbers weren’t pretty: a measly 11 mpg. That was the wake-up call I needed to confirm the engine was due for a rebuild.
The first time Big Blue's power plant has been outside the truck since she left the factory in Pontiac, Michigan some 34 years ago.
For this critical task, I turned to Steve Bird, a master of GM V-8 rebuilds. Steve’s not just a gearhead—he’s a fascinating guy with a diverse background. He spent much of his career at sea as a chef on car carriers, importing vehicles from around the globe.
I first met him at his Tiverton shop, Little Rhody Pasta, where he crafted fresh pasta that kept me coming back for more. Over plates of fettuccine, I learned about his passion for restoration. His pride and joy? A stunning 1994 red “farmer bed” pickup he’d brought back to life after buying it from a local farmer who’d blown the engine trying to free it from a muddy field.
In early spring 2024, I entrusted Big Blue to Steve’s capable hands. He dove into the rebuild, upgrading the engine with a high-volume oil pump and dual timing chains. New valves, pistons, connecting rods, and main bearings rounded out the overhaul.
A before and after of the valves, actually kind of amazing the engine ran as good as it did prior to rebuild
In this video, we get a first look at Big Blue's power plant. Approximately 300k miles took its toll.
Eight newly minted pistons, ready for install, the double timing chain for extra durability and the botton end, main bearings installed.
The "new" heart of the beast, assembled and ready to return to Big Blue and in its new home as it awaits radiator, hoses and belts
And now the moment of truth. "I think I want to pee myself" Its Alive!!!!
The Restoration of Big Blue’s Body
“Brighto! Makes Old Bodies New” – Dizzy Doctors, Three Stooges Short, March 19, 1937
With the power plant humming after Steve Bird breathed new life into her, it was time to elevate Big Blue’s restoration to the next level. This involved integrating the bed, replacing the fenders, and tackling any hidden rust on the truck.
The first step was preparing the truck for the body shop. That’s when I uncovered a problem that, frankly, looked grim.
The driver's side floor, almost gone completely.
The passenger side floor, badly damaged by rust.
I knew the cab’s rocker panels—the metal beneath the doors on both the passenger and driver’s sides—would need to be cut out and replaced due to extensive rust. But the real question was: how bad was the floor of the passenger compartment?
In April 2024, I removed the rubber floor mat inside the cab. What I found was devastating. On the passenger side, there was a 4” by 2” hole on the transmission hump that required a metal patch. Fortunately, the surrounding metal appeared solid.
The driver’s side, however, was a different story. The entire floor forward of the seat was ravaged by rust, requiring a complete replacement from the seat to the firewall.
Welding a new floor would be risky and impractical. GM had installed jute insulation where the floor meets the firewall, and a single errant spark could ignite it, causing a fire. Instead, the rusted metal would need to be cut out, and at least the upper portion of the replacement floor would be riveted in place and sealed with body caulk.
Additionally, both front fenders needed replacement. While the originals could potentially be repaired, they wouldn’t address the long-term rust issue and would remain vulnerable. Patching them seemed futile when new original equipment manufacturer (OEM) fenders could be sourced with some effort.
Aftermarket fenders were available online at a fraction of the cost—under $100 per fender compared to over $500 for OEM. However, their fit often fell short of GM standards, and I wanted Big Blue to be as close to factory-new as possible. OEM was the only choice, despite the price difference.
My ill-fated DIY attempt to install an aftermarket fender. The fit just wasn't right. Only OEM would do.
With the new fenders ordered and the old ones removed, I delivered the truck to Ken’s Autobody on May 3, 2024, for an extended stay.
Ken offered a reasonable rate for the work, though some costs were beyond his control. For instance, automotive lacquer paint prices had skyrocketed, with the paint alone costing over $2,000.
His affordable pricing came with a catch: insurance repair work took priority, so he would work on Big Blue during lulls between customer cars.
As with the 2010 restoration, the truck needed new rocker panels, a repaired driver’s side floor, a patched passenger side floor, and replacement of both cab corners.
Prepping to cut holes in Big Blue's Jerry's Bumpers step bumper for installation of high-intensity back-up lights.
New high-intensity back-up lights later installed in the step bumper.
While the truck was at the body shop, I turned my attention to Jerry’s Bumper step bumper. I cut two holes for high-intensity LED backup lights and installed super-bright license plate lights.
I also began stockpiling parts for the next phase of the project. These included new LED taillight assemblies, new chrome wheel well openings, new rearview mirror, chrome done handles, four Cooper tires, and wheels originally designed for the Chevrolet Astro Van. These wheels, bearing a GM part number, were used on some GM pickups in the 1990s.
New stuff! Rearview mirror with back-up camera, Retrosound radio, LED taillights and Chevy Astro Van 15" wheels.
May 3, 2024, Big Blue, looking a bit like an extra from the movie Road Warrior leaving my home for an extended stay at Ken's Autobody. To pass the time on the trip, I flipped on the radio. The first song that came on was Kane Brown's "Miles on It" about a newly restored Chevy truck, "with a truck bed wide as a California king." May 3, 2024 was the exact day the song was released.
Additionally, I ordered a rearview mirror with an integrated backup camera display and a Retrosound radio. The radio mimics the truck’s original dash aesthetics but offers modern Bluetooth connectivity for hands-free calls and USB charging.
May 3, 2024, marked the start of a nearly six-month wait for Big Blue’s new body.
As parts piled up in the garage, the wait for Big Blue’s return continued.