Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Very cool Ian.

Great progress, you must be very pleased so far.

Been chatting with Paul in Ada, OK today and getting step by step reports and his repairs made me realise, I have soooo much to learn still.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Gentlemen, thank you for the positive comments, they are really appreciated :thumbs:


In between work and other commitments I have managed a little progress this week. I have finished welding the corner, unfortunatley my rust went beyond the repair panel, leaving me a gap to fill.

Attachment 1545797

I folded up a repair section which after a bit of tweaking ended up fitting pretty well (if I do say so myself:))

Attachment 1545798

Attachment 1545799

I got it (almost) tacked in place when I ran out of welding gas, I don't know why that should come as a surprise but it always does, I really should pay more attention to the gauge :lol:

Attachment 1545800

But every cloud has a silver lining. I decided to use the spare time to tidy my garage and found this.

Attachment 1545801

It's a Massey Fergusson (AGCO) tool box, a place I worked used to make them. It may come as no surprise but in the best Johnny Cash (One Piece at a Time) traditions these were at the top of everyones "take home" list. So much so that if we had to ship a batch of 100 we would make 125 just to make sure there was enough left over to ship:lol:

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Looking good Ian. Have you to do the other side as well?

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

It's a Massey Fergusson (AGCO) tool box, a place I worked used to make them. It may come as no surprise but in the best Johnny Cash (One Piece at a Time) traditions these were at the top of everyones "take home" list. So much so that if we had to ship a batch of 100 we would make 125 just to make sure there was enough left over to ship:lol:[/QUOTE]

That's funny :metal:

Also nice work on the patch panels Ian.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Thanks Bill, yes I have the other side to do, it's nowhere near as bad but I'll probably end up changing just as much metal.

Thanks Dale a long way off your standard, but atleast your thread gives me something to aim for :metal:

Another quick update, I finished welding the patch into the cab (the weld still needs dressing properly but I've a bit of panel beating to do first to square up what still remains of the damage)

Attachment 1547447

Another job on the cab floor I have made some progress on is filling some holes. There are about a dozen 9/16" holes in the cab floor next to the bolts for the seat runners, my guess is a PO has had bucket seats fitted.

Luckily having worked in a stamping shop and being an absolute magpie, I still have some slugs of various sizes.

Attachment 1547448

They are ideal for this kind of job, just hold them in place with a magnet until tacked then

Attachment 1547449

Now you see me

Attachment 1547450

Now you don't

Attachment 1547451

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Never ends does it.

Looking good though Ian.

I look forward to getting the little jobs done and out the way before tackling what will be a challenge on my body panels.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Well it’s been a while (over 3 months) since I updated my build thread. Progress has been slow and time limited and I wanted to have something to report before doing the update (just didn't think it would be this long :lol:).

The rust in the floor turned out to be a whole lot worse than I imagined and although there weren’t actually that many holes, the steel around the holes was generaly so pitted it was easier to replace sections than try to repair holes.

Attachment 1576898

So there's been lots of this

Attachment 1576899

And this

Attachment 1576901

And this

Attachment 1576902

But now it looks like this :metal:

Attachment 1576903

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

I have also repaired the passenger side fender; you may recall from earlier in my thread the P/O’s wonderful repair. (the snot welded patch staight on top of the rust :banghead:)

Attachment 1576909

He had actually welded it so badly that the area around the repair was very badly warped. I have a repair section but decided not to use it,

Attachment 1576910

The fender strengthener was really badly pitted on the inside (although it actually looked great from the outside so that was going to have to be looked at too)

Attachment 1576913

Attachment 1576914

Still a bit of hammer and dolly work required but I don't think I'll avoid some filler :lol:

Attachment 1576915

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Nice work Ian. It's a good idea to replace all the pitted sheetmetal.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Thanks Dale and you're absolutely right, some of the pitted steel was down to 20% of the original thickness

I've cut out the pitted and holed sections from the fender support and replaced them with new metal, it would have been quicker to replace the whole thing with a new one but a new one would take 2 or 3 weeks to arrive in the UK. :waah:

Attachment 1580640

Attachment 1580641


When the welding was done I had the fender and "new" door, kindly donated by Rian, (thanks mate :metal:) media blasted. I used Rix Media and Soda blasting, it's a local company owned and ran by a local drag racer, petrol head, car enthusiast and all round good guy. He did a fantastic job, I would recommend him to anyone.

Attachment 1580642

Once I got them back I coated the inside of the fender with stone guard. The fender still needs a lot of work but will straighten out OK.

Attachment 1580643

The door has more holes than a beatles song (cryptic clue, answers on a postcard :lol:). but is way more straight than the one that came with the truck and I have a repair section (courtesy of Ta2Don :thumbs:) which will get rid of 95% of the holes.

Attachment 1580644

I'm not having as much fun as Rian but Hey-Ho

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

That tin worm gets every we're don't know what I'm gonna find when I start mine.
Great progress :metal:

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Thanks Pete, you're absolutely right, here are a couple of unexpected ones, I couldn't find anyone who did repops and my local breakers didn't have any either :lol:

This bracket bolts to the top of the fender and actually looked great until I hit it with a wire brush,

Attachment 1581089

nothing else for it, I had to make one.

Attachment 1581090

The tin worm in the L bracket that holds the fender seal was a little easier to spot :haha:

Attachment 1581091

had to make one of these too

Thing is they're not flat, but luckily for me the one part that hadn't completely disintergrated was the shaped part, which gave me something to use as a pattern.

Attachment 1581092

Came out Ok in the end

Attachment 1581093

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

I had the same with my rear fenders along the bottom edges,
I did fix them but there is some filler in them so didn't strip them all the way back until I rebuild the old girl fab work looks good i am sure I will be doing
Some of that lol

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Nice job fabricating those parts Ian. Probably fit better than repops and cost you less

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Thanks Dale

Before I refit the fender I'll have to fit fresh seals. The original seals are stapled in place. I discovered that the factory staples have exactly the same pitch as T50 staples that you would use for upholstery DIT and the like. I don't have a staple gun man enough to punch through steel, but I had a cunning plan :lol:

I glued the new rubber seals to the steel mounting plates with a contact adhesive (I would not recomend this as it reacts with the paint :waah:) Luckily it's hidden under the seal

Then using the original staple holes ran a 1/16" drill through the new rubber seal.

Attachment 1582316

After that it was a simple job to push some new staples throught both steel and rubber and clench them over with a paralell punch.

Attachment 1582317

Attachment 1582318

Before and after

Attachment 1582319

Attachment 1582320

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

I could find a match for the original clips to mount the fender seal here in the UK so I used these "fir tree" clips.

Attachment 1582338

Because they're a paralell clip you have to enlarge the holes on the seal bracket to the same size as the ones in the fender support (from 5/16" to 3/8")

They're a tight fit so you'll need a mallet to tap them in

Attachment 1582339

And they're plastic so no rust issues:metal:

Attachment 1582340

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

A quick progress update, (well probably about 4 updates back to back :lol:)

I have now finished the passenger side floor repairs so while painting the fender seal bracket I gave it a quick coat of body colour.

Attachment 1595941

I trial fitted the fender which still fits well, before beginning the door repairs.

Attachment 1595942

First job on the door was the rear corner, the blasting revealed a couple of holes but the door seams were good so I only removed the rusted area preserving as much of the original door (and door profile) as possible.

Attachment 1595946

Attachment 1595947

Attachment 1595948

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

The front skin needed a small repair too

Attachment 1595949

Attachment 1595950

The front corner proved to be a little worse, with the rust extending into the hinge area and beyond the area covered by the repair panel.

Attachment 1595951

Attachment 1595952

I had a full door bottom but decided to only use a small section as the rest of the door bottom is in good shape.

Attachment 1595954

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

I made the upper section which turned out ok.

Attachment 1595957

Attachment 1595955

Attachment 1595956


The front skin needed a small repair too

Attachment 1595958

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

The next job was the speaker hole, Don had given Rian a section from one of his old doors to use as a repair panel luckily for me (thank you gentlemen) the panel came with the door.

Attachment 1595959

I have to say getting it lined up was just about the most “fiddly” job I’ve ever done

Attachment 1595960

Attachment 1595961

It’s still not finished but this is what it looks like at the moment,

Attachment 1595962

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Ian, I have to admire your skills and problem solving solutions when parts just are'nt available off the shelf

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Just taking my rear brakes apart. First time on the truck in a while.

That is a massive amount of time and progress Ian.

Well done.

I still have a hole to correct on my drivers door, and suspect I will find as much rust and damage to repair. I know my rear bed panel has up to 10mm of filler......

Really good to speak with you yesterday as well.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Great work mate!:mm: Glad I could be a contributor even in a roundabout way...:lol:

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Looking good Ian lots of progress dreading what I will find when I pull mine apart got some holes in the same places :smoke:

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Nice work Ian. Your getting there.

Beginning to wish id done what your doing rather than take the easy way and reksin and whole bottoms. May have needed less filling and sanding!!!

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Thanks Michael, I still need to check out your new truck was planning a ride over with Paul sometime soon

Thanks Rian

Thanks Don and I've still got the section of door skin to fit too, stay tuned.........:lol:

Thanks Pete, hopefully you won't find as much as I have, you would not believe some of the "repairs" I have found :waah:

Thanks Bill, I still have a fair bit of filling and sanding to look forward too, I've tried all different sorts of filler and tools but it's hard work no matter what you do :lol:

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Nice job on the doors Ian . The floor looks great . You'll have it back on the road soon at this rate .

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

The following post is definitely the most pictures for the least amount of time spent on a job I have posted so far :lol:

I am still doing repairs to the passenger door, one of the little jobs that needed doing was to replace the captive nuts that hold the inner door panel in place. A common fault on our trucks, some of the screws had rusted in place and had to be drilled out to remove the panel.

Attachment 1605028

Now your probably thinking 1/4" x 20 unc captive nuts.... no big deal, well in Europe they are a lot less easily available than you may think, we're all metric over here .....(I blame the French it's all their fault :lol:)

This whole job took 20 minutes start to finish and was done with stuff I had lying around so cost $0.00.

I started with a piece of 1" x 1/4" flat stock marked at 3/8" and centre punched,

Attachment 1605029

Drilled out to 0.2"

Attachment 1605030

I then ground a step on each side (using a 24 grit disc) leaving a 3/8 raised section down the centre

Attachment 1605031

and then cut it into 3/8 "strips"

Attachment 1605032

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

these were then tapped to 1/4" x 20

Attachment 1605033

Attachment 1605034

I was originally going to spot weld these in place but decided JB Weld would do the job

Attachment 1605035

A little dab on each end and "presto"

Attachment 1605036

Attachment 1605037

So 20 minutes later another job ticked of the list :thumbs:

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Got any Spares?

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Very clever work!
a few of mine had twisted out on disassembly, but I only needed to run a tap through them & epoxy them back into place.
Ingenuity at its finest!

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Thanks for sharing Ian.

I had a few of mine self destruct, despite my most gentle effort

Will most certainly remember this post when I get to this point.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Not at the minute but I'm sure to be making some more :lol: how many do you need ?

Thank you, living in England ingenuity often = $ saved :thumbs:


Thanks Rian


Today I had a couple of hours of truck time, so decided to tackle something that’s been on my “to do” list for a while. It was one of those jobs that you know is just going to end up bigger than it looks. The truck had a few bubbles on the top of the passenger side B pillar, which turned out to be holes

Attachment 1608369

Which turned out to be a bit of a “tin worm” infestation. Nothing else for it keep cutiing until you find good metal

Attachment 1608371

Attachment 1608370

I folded the inner piece first which was tacked

Attachment 1608372


and then finish welded.

Welding under the gutter was tricky, I after ginding the weld to blend it into the gutter I found a couple of holes, access wearing my welding helmet was arkward so I ended finishing the welds using the position the torch, close your eyes, pull the trigger method. Please don't mix up the steps as I did once, you'll find position the torch, pull the trigger (forget to) close your eyes, will leave you blind for a good 10 minutes :dohh:

Attachment 1608373

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Did the same for the outer piece, I include a few “spot weld” holes so that the finished repair will match,

Attachment 1608378

I got it to here ………….and then ran out of gas :waah:

Attachment 1608379

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Looking good Ian. I love how a paint bubble ends up being a 2 inch hole by the time you find something to weld to

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Very nice job Ian . There can't be much left on that cab you haven't repaired . Looks like you are getting there though. Will we all be done by the end of the year though that's the big question.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Nice work! You are getting all those tin worm issues taken care of in style.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Your work looks great Ian. Find a problem, figure out a solution and get it done.
Can't wait to see the next episode...

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

You are a metal craftsman. Great thread about a very nice truck.

Re: Ian's Tennessee Honey '64 Short Box Step-side - England
 

Gentlemen. thank you for all of your kind comments, I am enjoying the challenge but I must say at times this old truck is testing the limits of my (limited) skills

Truck wise I’ve had a bit of a “slow start” to 2017, I managed to get a piece of rusty metal in my eye, which resulted in a 6 hour visit to the ER. The metal was dug out but the wound ended up becoming infected so I’ve been sporting an eye patch. Which I thought made me look like this

Attachment 1624961


But my wife reckoned I looked more like this

Attachment 1624962

Oh, and I had a chest infection too.

Anyway, I finally got back on the truck last weekend and got the pillar repair finished, if I say so myself it may be the best repair on the truck so far.

Attachment 1624964

So back onto the door I got from Rian, the media blasting had revealed more holes than expected in the door.

Attachment 1624965

Don (Ta2Don) had supplied a repair patch so I just had to decide what to weld up and what to patch.

Attachment 1624966