The High School Hauler That Stuck Around

Kyle Hunsaker’s 1976 Chevrolet C10, built over five years in Mesa, Arizona, is a frame-off custom truck build featuring a 2004 5.3L LS engine swap, Porterbuilt Level III air suspension, AccuAir E-Level management, and 24-inch Raceline Speedster 5 billet wheels. Built by Hunsaker and his longtime friend Justin Heller under their Build Bros collaboration, the C10 represents a complete mechanical and cosmetic transformation of a truck Hunsaker has owned since high school.

FEW OF US ARE LUCKY ENOUGH to still own the ride we had in high school. More often than not, it’s a simple matter of making the dumb decision to sell our pride and joy to go onto the next shiny thing that catches our attention. It happens to all of us. Well, most of us.

Kyle Hunsaker of Mesa, Arizona, was in it for the long haul with his ’76 Chevy C10, having bought it right around the time he first got his license. Well, actually, this is the second C10 he had in high school—the first was stolen and never recovered, so this was its replacement.

Kyle’s main goal was to have a fun, reliable hot rod, which meant not only having a dependable drivetrain, but a foolproof suspension as well. It didn’t take long for him to decide on a Porterbuilt Level III air suspension setup, which was installed by both Kyle and Justin Heller, who go by the name Build Bros when they’re tackling truck projects together.

The Porterbuilt Level III kit is the brand’s most comprehensive air suspension package, designed for builders who want full system integration rather than a piecemeal approach. Porterbuilt, based in Idaho, is widely regarded in the minitrucking and bagged truck communities for their bolt-on precision and weld-in chassis kits designed specifically for classic trucks.

The Bros pulled the cab and bed off to get unobstructed access to the chassis before installing the Porterbuilt chassis and air ride parts, which went on without a hitch. They also handbent all of the air lines and installed a Boyd’s Welding fuel tank, along with the new fuel lines and even a full Wilwood brake setup up front and on the narrowed rear end.

Of course, all of this work was to make sure that the 24×9 and 24×15 Raceline Speedster 5 billet wheels and Pirelli tires would tuck nicely behind the fenders and bedsides, which they did!

Seeing the frame finally sitting on the ground was all the motivation Kyle and Justin needed to keep going. Kyle had already picked up a 2004 5.3 LS and a 4L60E built by Jason Bowman at Big 10 Garage, so it was just a matter of cleaning everything up, bolting on some Dirty Dingo LS swap mounts, an Ingenuity Fab Shop transmission crossmember, and dropping everything onto the prepped chassis. Slosh Tubz firewall fillers were welded in over at Matador Rod Rod & Customs, which really cleaned up the previously busy stock sheetmetal.

Now, all of this work was done very carefully, since Kyle had already had the truck painted by his buddy Kyle Danielson prior to tearing it apart. With shaved door handles, a molded-in roll pan, and a few other subtle tricks underneath the shiny silver and black paint, Kyle did not want to have to do any of it over again!

Over the years, he has slowly worked on it as time and funds allowed, but Kyle really got down on it after deciding to rebuild it from the ground up. It would take five solid years, but it would be time well spent.

Funny story: When we asked Kyle which specific colors were sprayed, he quickly admitted, “It was just some leftover silver and black paint that Kyle had in his shop!” Talk about using what you’ve got! Regardless, it was just the right combination to give the truck a classy look.

Check out these top upgrades for your C10 LS engine swap.

The interior had been done a while back and just needed some freshening up, and it sports something that we wish we’d see more of these days: tweed everywhere! That, in combination with the Zolatone-painted gauge panel and a Budnik steering wheel, and you’ve got a rad retro treatment that oozes nostalgia. The only thing cooler is the Vintage Air climate control, which is a necessity during those hot Arizona summers!

Build Lessons: What Kyle and Justin Learned

For Kyle Hunsaker and Justin Heller, this ’76 C10 was more than a restoration it was a five-year education in truck building. Here are the key skills and lessons the Build Bros developed during the project:

1. Bending and Installing Custom Air Lines
Hand-bending stainless or nylon air lines for an air suspension system requires patience, the right tools (a quality tube bender), and careful routing to avoid heat sources and moving parts. Kyle and Justin tackled this from scratch, learning how to plan line routing before cutting any material.

2. Building a Custom X-Pipe Exhaust
Custom exhaust fabrication involves understanding pipe sizing (typically 2.5 to 3 inches for a 5.3 LS), collector placement, and merge angle for X-pipe crossover efficiency. Using Magnaflow mufflers gave the build a polished tone without requiring custom muffler construction.

3. Fabricating and Flaring Brake Lines
Hand-forming brake lines is a skill with real safety implications. Kyle and Justin learned double-flare and/or AN fitting techniques to create the custom brake lines required by the Wilwood front setup and narrowed rear end configuration.

4. Working in Phases Without Damaging Finished Work
Perhaps the most unusual aspect of this build: the truck had already been painted before the mechanical rebuild began. Working around finished paintwork required planning every lift, support, and movement carefully to avoid scratches or damage a discipline that most builders only develop after making costly mistakes.

“It was our first big build,” Kyle says. “From building our own brake lines to building our first X-pipe exhaust… [We] built it from the ground up, but we had a lot of help along the way.”

Looking for more inspiration? Check out this incredible custom Chevy C10 build featuring a completely different approach.

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BUILD AT A GLANCE: 1976 CHEVROLET C10

Category	Specification
Vehicle	1976 Chevrolet C10
Owner	Kyle Hunsaker, Mesa, Arizona
Builder	Kyle Hunsaker & Justin Heller (Build Bros)
Build Duration	5 years
Engine	2004 GM 5.3L LS-based V8
Camshaft	Brian Tooley Racing (BTR) performance camshaft
Transmission	4L60E (built by Jason Bowman, Big 10 Garage)
Engine Mounts	Dirty Dingo LS swap mounts
Transmission Crossmember	Ingenuity Fab Shop
Suspension	Porterbuilt Level III air suspension
Air Management	AccuAir E-Level system
Compressors	VIAIR (dual)
Brakes (Front)	Wilwood disc brake setup
Rear End	Narrowed
Fuel Tank	Boyd’s Welding custom
Exhaust	Custom X-pipe with Magnaflow mufflers
Wheels (Front)	24×9 Raceline Speedster 5 billet
Wheels (Rear)	24×15 Raceline Speedster 5 billet
Tires	Pirelli
Paint	Silver and black (sprayed by Kyle Danielson)
Body Modifications	Shaved door handles, molded roll pan
Grille	OEM 1973 C10 grille (swapped from stock ’76)
Interior	Tweed upholstery throughout
Gauge Panel	Zolatone painted
Steering Wheel	Budnik
Climate Control	Vintage Air
Firewall	Slosh Tubz fillers (installed at Matador Rod Rod & Customs)
Air Lines	Hand-bent by Build Bros

Manufacturer Resources:

• AccuAir Suspension
• Raceline Wheels

Frequently Asked Questions

What engine did Kyle Hunsaker use in his 1976 C10 build?

Kyle’s ’76 C10 uses a 2004 GM 5.3L LS-based V8 engine, a popular swap choice for classic C10s due to its modern reliability, strong aftermarket support, and relatively low cost compared to other performance options. The engine received internal upgrades including a Brian Tooley Racing (BTR) camshaft.

What transmission is paired with the 5.3 LS in this C10?

The build uses a 4L60E automatic transmission, built by Jason Bowman at Big 10 Garage. The 4L60E is a common pairing for LS-swapped trucks in street/show applications due to its compact size and wide availability.

What air suspension system does the ’76 C10 use?

This C10 runs a Porterbuilt Level III air suspension kit, managed by an AccuAir E-Level system fed by dual VIAIR compressors. The system allows the driver to adjust ride height electronically, enabling the truck to sit slammed for shows or raised for driving.

What wheels and tires are on Kyle’s C10?

The truck runs 24×9 inch Raceline Speedster 5 billet wheels up front and 24×15 inch Raceline Speedster 5 billet wheels in the rear, wrapped in Pirelli tires. The rear end was narrowed to accommodate the wide rear wheels while maintaining proper fitment.

What is the difference between a 1973 and 1976 C10 grille?

Kyle swapped his stock ’76 C10 grille for an OEM unit from a 1973 model. Among square body Chevy enthusiasts, the ’73 and ’74 grilles are widely considered to have more refined detailing than later grilles, making them a popular upgrade for trucks from ’75 onward.

How long did this C10 build take from start to finish?

The complete frame-off restoration and build took approximately five years, with Kyle Hunsaker and Justin Heller working together under their collaborative name “Build Bros.” The extended timeline allowed for careful work and learning, as this was the duo’s first major build project.

What does AccuAir E-Level do?

The AccuAir E-Level is an electronic air suspension management system that allows drivers to set, save, and automatically maintain specific ride heights. In Kyle’s C10, it provides precise control over the suspension, making it easy to lower the truck for a slammed show stance or raise it for everyday driving.

What interior materials were used in the ’76 C10?

The interior features tweed upholstery throughout, a Zolatone-painted gauge panel, a Budnik steering wheel, and a Vintage Air climate control system. The tweed and Zolatone combination gives the cabin a vintage aesthetic that complements the truck’s overall classic styling.