After 8 years, we are back to building a new version of Tow Mater - this one better than ever before!  To make this replica look even more like the cartoon version, we are moving away from the use of a Chevy truck, and instead going with an International cab pair with heavily modified Chevy fenders.  This is going to give Mater the most correct look we (or anyone else) have ever created.

Instead of using the 50's chassis and components, we started with a 79 Chevy 1-ton chassis.  This gives us a more modern suspension, brakes, and power steering.  Plus, there is a lot of support for swapping in an LS platform drivetrain in these chassis - which is what we are going to do.  First the chassis was shortened 20 inches, then the cab was set in place and channelled over the frame to keep it level.  The 5.3 LS engine and 4L60E trans were mounted next, then the brand new 57 Chevy front end and fenders were attached.

The Chevy fenders and International cab did not match up, so extensions of the fenders were created and welded to the doors to extend and continue the body lines of the fenders.  The headlight areas were also heavily modified to create the correct "Mater" look.  By cutting off the eyebrow area over the headlights, then using a board and jack to reshape the headlight area, we ended up raising the headlights 4 inches and making the openings round - completely removing the eyebrow look and making these fenders almost unrecognizable.

The wheel openings didn't quite line up with the wheels, so each fender was sectioned and moved to center the fender over the wheel.

Now the fun part - the mouth.  Starting with a big piece of sheetmetal for a blank slate, the mouth is designed by first creating a dimple on the right side, outlining the lips with 1/2" round tubing, bending the sheetmetal to form the lips, and then making the trademark buck teeth.

Front bumper is created and welded up, then the headlights were finished off.  The driver's side light is missing on Mater, so that one is left with a flat look, while the pass light is given a frenched in look using the headlight ring from an early 50s chevy truck.  The smaller teeth were made from plastic, using a mold created from a clay model we carved.  

Now onto his head.  Mater always has a "tilted" look to his head, so to achieve this, the roof was split front to back, and left to right, then rewelded in place with a lift on one side.

The bed is completely custom fabricated since nothing exists that looks like Mater's tow bed, so using an old tow bed would not be correct.  It is framed with some 2x2 square tubing and made from 10 gauge steel sheet that's about 1/8" thick.  Pretty simple design.  The fake gas filler is molded into the driver's bedside.  The big Tulsa winch is bolted down with it's chain drive mocked up through the bed floor; and the headache rack frame is welded in place.