|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Man............. this interior looks so sanitary. No way was it close to this smooth and clean brand new from the factory. This truck is turning out fantastic.
Well done sir Marc |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
I pulled the column to finish up the filler panels. https://i.imgur.com/qzVw0wBh.jpg While the pedal assembly was out I found a spot to mount the clutch safety switch. Had to carve out a spot for the stem to make enough clearance, so I used a 1/2" round carbide burr to make the face of the cut concave, that way the convex face of the stem will always center itself on the pedal arm. https://i.imgur.com/OfkCv2Sh.jpg https://i.imgur.com/O8ya65kh.jpg Forgot to take pics, but I chopped the clutch pedal pad off and raised it up to match the height of the brake pedal pad. Also slightly tweaked the brake pedal pad to get it inline with the clutch pad. https://i.imgur.com/K80RuE4h.jpg I ordered cowl bottoms a few weeks ago but UPS sent an email about the address being wrong, so delivery was delayed until last week. They're very nicely made, probably the best fitting patch panels I've used. https://i.imgur.com/D577c6Ih.jpg https://i.imgur.com/3xDoa3mh.jpg Trimmed, shipping primer stripped, two coats of epoxy applied, and welded on. https://i.imgur.com/3Qllo4Jh.jpg https://i.imgur.com/JbMGkxQh.jpg https://i.imgur.com/MBWnzEih.jpg https://i.imgur.com/O9WsAlNh.jpg https://i.imgur.com/cYvfXPuh.jpg The cavity is accessible so I brushed on a couple of coats over the welds and soaked the seams to let epoxy wick in and seal up the spot welds. https://i.imgur.com/Og5rmNch.jpg I made a panel to mount the fuse box so there would be no fasteners through the firewall. https://i.imgur.com/ij2MAPUh.jpg https://i.imgur.com/O5SwpYWh.jpg https://i.imgur.com/yScgbJuh.jpg Also deleted the original pressed-in wiper motor mounting boss- welded up the holes and welded a nut between a couple of fender washers to make a new mounting pad for the wiper motor. The accelerator pedal mount got welded in permanently after confirming that the location fits the owner. https://i.imgur.com/bGt6xcLh.jpg https://i.imgur.com/D9zRBDCh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
beautiful work as always.
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
This is going to be the nicest truck built!!!!
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Great job John...and great that you got cowl patches that actually work without having to modify them
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
Quote:
Quote:
The firewall to kick panel flange was really wavy around the spot welds so that was straightened, then I ground back the edges until the height of all the layers matched. (I thought more of this was visible, but it's mostly hidden under the inner fenders after test fitting them.) https://i.imgur.com/cXem22Hh.jpg https://i.imgur.com/iwdmyThh.jpg The flange of the cowl skin was wrinkled and uneven so I trimmed both sides before final blasting. https://i.imgur.com/26TSUejh.jpg https://i.imgur.com/Fkk7TvYh.jpg https://i.imgur.com/p0MCFh7h.jpg https://i.imgur.com/CYzbOxeh.jpg With those spots finished up I rolled it out and blasted the inner layers of the cowl sides that were cut open, and I lightly blasted over the floor, firewall inside and out to prep for two coats of epoxy. https://i.imgur.com/WWoPCMTh.jpg https://i.imgur.com/rMAjFNwh.jpg https://i.imgur.com/sHtp3Uph.jpg https://i.imgur.com/5KsG6o9h.jpg https://i.imgur.com/TevMIWDh.jpg I started bodyworking the firewall by skimming the upper face and flange. https://i.imgur.com/wMKAth6h.jpg https://i.imgur.com/Mwc0kumh.jpg Once both sides were filled/blocked into the correct shape and straight I masked off the inside corner and used a spreader with the corner rounded off to make an even radius from side to side. https://i.imgur.com/DV4Ik7ah.jpg https://i.imgur.com/hzVyPK9h.jpg https://i.imgur.com/tk4WOC2h.jpg Floor pan and tunnel welds smoothed up enough for Raptor Liner. https://i.imgur.com/RBGBzOLh.jpg Starting to straighten out the stamping distortion in the firewall. https://i.imgur.com/j8sF96Uh.jpg Another coat of epoxy to seal the filler and extend the 7 day recoat window. Both mom and dad have had covid for the last 2.5 weeks so I wasn't able to get much done within the first 7 day window. They're both doing much better now and things should be back to normal soon. https://i.imgur.com/lzLuSybh.jpg https://i.imgur.com/yy3dQSjh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
dang John...that epoxy looks as good as paint
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
You have a keen eye for detail. Things like that distortion between spot welds are things that I just think of as being the way they are built, and don't really notice it. Now I'm going to go look at my 96 Silverado and see if I notice imperfections that I never noticed before.
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
Quote:
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Hope your parents continue through to a full recovery 🙏🏾:metal:
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
X3...I missed the part where your folks had the coronas...glad they're doing better
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I hope your parents continue to improve John. Truck looks amazing.
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
Quote:
Quote:
Quote:
Appreciate the comments! Both are doing much better. Dad is still "running our of gas" as he says about midday but is otherwise doing well. Mom is pretty much 100% now. |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Good to hear..!!!!
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Yes, very nice to hear!
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Now that my fingertips have grown back enough to type out an update... This is the real reason shaved firewalls are so popular lol.
I finished skimming and correcting the distortion in the firewall, then shot it with a few coats of Clausen All-U-Need. I've been wanting to try it since it's waterproof and is supposed to sand easier than Slick Sand, which I believe it does now that I have some experience with it. https://i.imgur.com/zZLTuskh.jpg https://i.imgur.com/4laWmTEh.jpg https://i.imgur.com/9n8POj8h.jpg https://i.imgur.com/mKSPT2dh.jpg https://i.imgur.com/BrwSvbfh.jpg https://i.imgur.com/xrNK91yh.jpg The top section and it's flange was sanded flat up to 150 grit, keeping the edge of the paper slightly off the edge of the block to not sand into the corner and cut a sharp edge. https://i.imgur.com/cseSLxXh.jpg Guide coat applied, then the corner was sanded with a Durablock with a corner rounded to the correct diameter. Tape was used on the upper half of the block to keep the block from digging into the section that was already flat. Just the radius is shaped this way. https://i.imgur.com/tnVOUMLh.jpg I blocked the tops of the raised stampings first, using a block wide enough to cover the areas where a section split off when applicable to keep the two sections on the same plane. The inner flat sections were next, same approach using custom cut blocks to leave the corners untouched, then the inside corners were shaped after the inner flat was fully flattened. Forgot to get pics of all that. https://i.imgur.com/bDGxpeBh.jpg Brake brace details. I sanded the flats first, scribed a line of where I wanted the corner to start, masked on the line, then rounded the corner evenly top to bottom. https://i.imgur.com/w6RrwIzh.jpg https://i.imgur.com/YIS2diah.jpg https://i.imgur.com/DeN0a3Dh.jpg https://i.imgur.com/L5WeJ8Ph.jpg Some of the inside corners had large radii so I sanded a short durablock to the correct shape and used it to sand the corner. https://i.imgur.com/7CAgGvBh.jpg https://i.imgur.com/2Ku5NFjh.jpg The raised area around the heater box had four flat spots so those were blocked first, then guide coat applied and the outside corners blocked until they rounded into the flats evenly. https://i.imgur.com/ntytM56h.jpg https://i.imgur.com/yioOG2Zh.jpg https://i.imgur.com/84KvkSLh.jpg https://i.imgur.com/7m6t35Nh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Same process on all of the random shapes.
https://i.imgur.com/hXsdialh.jpg https://i.imgur.com/6ZJqH6Th.jpg https://i.imgur.com/0pnYJVah.jpg https://i.imgur.com/cm5o890h.jpg Top edge and corners of cowl masked on the flat then blocked out to establish a consistent starting point for the edge radius. https://i.imgur.com/GRI5xcnh.jpg https://i.imgur.com/rPwUdhuh.jpg Lower seam lip blocked straight. https://i.imgur.com/kk8uZprh.jpg With the shaping finished I shot a couple coats of black SPI epoxy to seal up the areas that were low and needed filler, and to make the surface somewhat reflective so imperfections could be addressed. Some of the lower areas have 80g stratches showing and weird sanding patterns; those areas will be hidden under the inner fenders and shot with Raptor Liner later on so they were only quickly sanded for adhesion, not to correct their shape. The gloss level of the epoxy will really help with being able to spot fix the areas that need touching up, then shooting a few light coats of red epoxy so it's ready to wetsand and paint. https://i.imgur.com/Ig7HGJgh.jpg https://i.imgur.com/EOxU0LPh.jpg https://i.imgur.com/BOvfJ7Ah.jpg https://i.imgur.com/Qtm7RxIh.jpg https://i.imgur.com/sIvAJt7h.jpg https://i.imgur.com/LNBJqg2h.jpg https://i.imgur.com/0LMWvDeh.jpg https://i.imgur.com/NQxjdcXh.jpg Back of the cab stripped and shot with epoxy. I left the drip rails and the cab corners bare since I'll be reworking those areas when fitting the doors. https://i.imgur.com/QX7DTv8h.jpg https://i.imgur.com/RZ3M9L3h.jpg https://i.imgur.com/I1paWzdh.jpg https://i.imgur.com/zw44ncjh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Unbelievable amount of detail work you put in the firewall..
I dont know why, guess I'm just weird, but I like the look of a factory stamped firewall and all the details of highs and lows over the slick/shaved firewalls |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Looks like perfection, you have a lot of patience...
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
You have patience and skills. When it's finished I hope you or the owner takes this truck to a show and parks it next to an original one so people can see the difference.
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Awesome work John!
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Super work, but I've come to expect nothing less.
Your comments on the shine of the SPI epoxy made me smile. When I shot it on my rear step fenders I noticed a couple small places that will need addressing before I move forward with them come paint time. I thought those suckers were flawless until then. Nothing major, but a few small places you can now see. |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
Quote:
Quote:
Quote:
Quote:
Quote:
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I did a quick/light blocking with 220 on the areas that were already pretty good, and 180/220 on a few spots that needed a little more flattening. 3-4 spots needed a small amount of filler, and it was ready for the last coats of epoxy to seal it and make it ready for wetsanding and paint.
https://i.imgur.com/vSFMcsnh.jpg https://i.imgur.com/YZg4m3yh.jpg I mixed in a bit of red epoxy on the first coat, then shot two more coats of black epoxy. When I wetsand it to prep for sealer/paint I don't want to sand through the epoxy layer, so I'll be able to stop sanding if I start seeing the red tinted layer. https://i.imgur.com/a5qXFXMh.jpg Checking the reflection for imperfections while it was still wet. That's the look of a man who's happy to be finished sanding such a detailed panel. :lol: https://i.imgur.com/okKrwfnh.jpg https://i.imgur.com/zYvf9arh.jpg The vid shows how flat each facet is. [youtube]5ye5g4ZEjvw[/youtube] The blocks used, plus the PVC tube with slots cut to make it flexible for the double concave area on the back of the cab above the rear window. https://i.imgur.com/hCBOLrSh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
With the firewall finished, I moved on to assembling the panels to start correcting panel fit and gaps. I mounted the cab back on the frame along with the front clip after blasting the header panel and doing a bit of initial straightening on the inner fenders. The fenders and radiator support are aftermarket and the fit so far is really good, I haven't had to do any cutting, bending, or slotting of holes to get them to bolt together.
https://i.imgur.com/4Al9ttjh.jpg The new hood hinges held me up from getting the hood mounted. The old hinges were super worn and sloppy so the hood would never stay in alignment if they were reused, and reproductions were available. Their fit left a lot to be desired... with the mounting flange flat against the firewall the lower mounting hole was off by half of the bolt diameter. https://i.imgur.com/xznAvdyh.jpg Tilting the hinge to show how far the flange needed to be bent to align the lower mounting hole. https://i.imgur.com/Z2TgIbvh.jpg When the two bolt holes on the main flange were lined up the inner mounting flange was also off; not just width-wise but the shape of the flange didn't match the angle of the firewall. https://i.imgur.com/mZBXZl4h.jpg https://i.imgur.com/ibozukoh.jpg https://i.imgur.com/gaSErXeh.jpg The curved lip on the back side of the inner flange interfered with the lip on the firewall so I reshaped it and ground it back to fit better, and so the edge had a shape that flowed better. https://i.imgur.com/aiHVaLPh.jpg After about 40 trips between the firewall and vise to tweak the flanges into shape the hinge finally fit flat against the firewall and all four bolt holes were in pretty good alignment. Now when the bolts are tightened the flanges won't pull or twist the firewall out of shape, and won't chip the paint from the edges digging in. https://i.imgur.com/YMZxf6Jh.jpg https://i.imgur.com/Eq1B9kyh.jpg https://i.imgur.com/2AAtlWhh.jpg Same process on the other side. https://i.imgur.com/zt1bZHWh.jpg https://i.imgur.com/dXNjWF8h.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Really nice work. The time it take to do all the adjustments for fit are well worth it in the end.
But, I think you need a few more sanding blocks..lol |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Nice work as usual!
|
Quote:
Posted via Mobile Device |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
Quote:
Quote:
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Long winded hood hinge updat, I'll break it up into a few posts. The reproduction hinges ended up not working out once the hood was bolted on. Long list of problems with them-
1: The joints were too tight. I had to use a 24" adjustable wrench slipped over the flange that bolts to the hood to get the hinges to open and close, even with the spring off. 2: The individual arms are thinner and flexed easily which let the hood shift from side to side. 3: Each hinge angled outward front to rear by 5-7 degrees, so with the hood bolted on the already stiff joints were then in a bind from the joints on both sides not hinging parallel to each other. The thin and flexy arms somewhat minimized this problem :lol: This also made the flanges that bolt to the hood misaligned with the holes in the hood. 4: The passenger side hinge wouldn't fully drop as far as it should, so the back edge of the hood was kicked up above the cowl. 5: The joints were eating themselves. I cycled the hinges a few hundred times with the 24" wrench hoping they would "wear in" and loosen up, periodically adding oil to the joints to flush out the metal shavings that were building up. They eventually loosened up some but not enough. 6: The supplied springs were barely capable of holding the hood open, and not able to hold the hood all the way open. The hood has a section cut out at the very front for rust repair, no emblem, and the paint is stripped so it's lighter than a finished/painted hood. The friction in the joints were the main factor in the hood barely staying up. A full weight hood wouldn't have a chance at staying open. 7: The stops that set how far the hood opens were not shaped correctly. https://i.imgur.com/mAa35ksh.jpg https://i.imgur.com/9zUY0VZh.jpg https://i.imgur.com/15PNbFTh.jpg https://i.imgur.com/IK9g82ah.jpg https://i.imgur.com/3f7vCk3h.jpg https://i.imgur.com/AodqEAFh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
WOW...that is pretty bad..I'm sure you got a clever solution though
|
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
After searching the Ford truck forum for hood hinge info it seemed like the hinge rebuilding companies that others had used in the past were no longer willing to rebuild this style of F100 hinges, I think due to the hinge pin's rectangle shaped end that is used to rivet the pin in place. So, armed with the Atlas lathe and Bridgeport I set off to rebuild them myself.
I'm not a machinist, and certainly not very educated on how to properly use a lathe or milling machine... anything I've done with the lathe until now was just to rough out parts with no real need for precision. Preparing to make the lathe work correctly and then learning to use it somewhat correctly involved binge watching mrpete222, This Old Tony, and Blondihacks on youtube. The Atlas lathe was in desperate need of a tune up to make accurate parts; nothing was worn, whoever had it before us never really set it up correctly. None of the gibs were adjusted so there was play in everything. Eventually with considerable trial and error I figured out how to make a hinge pin. I bought a Columbian 506 M2 vise awhile back but hadn't mounted it yet, so I went ahead and did that to hold the main hinge frame during the rebuild process. https://i.imgur.com/99OgGWth.jpg I also recently found and bought an old Delta carbide grinder so I could shape and sharpen my own hss lathe bits and tune up the brazed carbide tools that came with the lathe. This would come in handy on the longer pin that the spring is hung from. https://i.imgur.com/24PK4Fbh.jpg Once back to the shop I started cleaning it to see if I could get it back down the the original paint. I'll get around to cleaning up the rest of it eventually. https://i.imgur.com/MoeLzTSh.jpg https://i.imgur.com/yxcVdmlh.jpg https://i.imgur.com/LUmsPMUh.jpg I checked the hinges on the parts truck and they were tighter than the original pair so I started with those. https://i.imgur.com/1rqjufoh.jpg The arms fit flat against each other, which creates wear and friction. I addressed this during the rebuild. https://i.imgur.com/Rpf7B2Qh.jpg https://i.imgur.com/RUwMKoUh.jpg I carefully ground down the riveted end of the pins, and used the mill in the tighter areas where the grinder wouldn't fit. https://i.imgur.com/x3lLzpAh.jpg Pressing out the pins. https://i.imgur.com/r3k5P4nh.jpg Tons of wear and gouging. The metal was deeply pitted, likely from the metal galling. https://i.imgur.com/x7yl0N2h.jpg https://i.imgur.com/SJnK5Wch.jpg https://i.imgur.com/nt9rnYlh.jpg https://i.imgur.com/y4YymOPh.jpg The link between the two main arms was thick enough to rub both arms, removing the coating and causing friction. https://i.imgur.com/7gZc2Z6h.jpg The measurements show how worn the parts were. https://i.imgur.com/Qq3TjWdh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I just knew you had a John fix for those..!...love some machine shop action
Is your arbor press bolted down?..I flipped a 5 ton arbor at work awhile back,, pulled the anchor bolts up outta the concrete.. yeah it broke the ratchet and handle off |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
Flipped it?!? You do know that five tons is what the press is rated at, not how much weight you apply to the handle, right? :lol: This one is clamped to the table on the other side, I didn’t want to mount it to the table full time since the vise is already taking up some real estate. It doesn’t take much tension to pop the pins out so I figured clamping it would be adequate. I’ll post more details on the hinges tomorrow, they’re already finished and the pics are uploaded but I gotta get some sleep so I can be up early to drive over near Atlanta to pick up a Heck nibbler/duplicator, apparently the Iron Fever itch wasn’t scratched well enough by yesterday’s 1920’s/30’s Boice Crane 14” bandsaw purchase… |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
haha.. it is a floor mount arbor press..took a forklift to stand it back up..I figure stand and all its probably close to 1000lbs...they did a investigation..being that it was a at work deal,,
Found that the drive in anchor bolts failed.. |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Got the Heck unloaded, need to build a table for it and the new bandsaw.
https://i.imgur.com/276X4Cfh.jpg It matches the big bandsaw pretty closely. https://i.imgur.com/MVVdovrh.jpg https://i.imgur.com/SFuHpU5h.jpg Back to the hinges. The arms were out of alignment, none of the pivot points were parallel from one end to the other. Some had high and low spots along the friction surfaces. https://i.imgur.com/Bo996bch.jpg https://i.imgur.com/zdVVBZLh.jpg https://i.imgur.com/47DD3wHh.jpg https://i.imgur.com/KcorrFoh.jpg After straightening. https://i.imgur.com/yU5vxrQh.jpg https://i.imgur.com/EPDMrqFh.jpg All of the areas that were worn were welded up and ground/filed smooth. The holes were all reamed to make the exactly round again. https://i.imgur.com/dETALHyh.jpg https://i.imgur.com/FDaQxv4h.jpg https://i.imgur.com/YY6a4Krh.jpg https://i.imgur.com/JWsTbAFh.jpg https://i.imgur.com/Mm1jGQqh.jpg Flatness was checked against a block of steel with a machined face. https://i.imgur.com/fjGcvlrh.jpg The pins were machined from 1" steel bar. I sized them for about .002" clearance for minimal play and room for grease. I also added .030" length to the shoulder so I could add a washer cut from UHMW. This will slightly cushion the joint, space the arms apart so they don't rub the paint off each other, and will reduce friction and wear in the joint. https://i.imgur.com/xOiSdduh.jpg .030" UHMW sheet from McMaster Carr. https://i.imgur.com/pwhnNmGh.jpg Drilling/tapping for 5/16-24 hardware to hold the joints together. The original pressed rivets are not a precise way to hold the joints together so I didn't want to copy that aspect of the hinge pins. https://i.imgur.com/IAMb5T6h.jpg https://i.imgur.com/SPLI3JWh.jpg Milling the square ends that set the depth of the pin. This determines how tightly the joint is assembled so it was critical to measure the arms, UHMW washer, and on the main frame the offset of the raised friction surface. Too deep and the joint froze up, and the joint was too loose and wobbled if the depth wasn't cut deep enough. I ended up cutting the step slightly too low on purpose so I could remove material from the arms to incrementally loosen up the joint until it there was no play but no binding. https://i.imgur.com/tJPIiFeh.jpg Compound set to 12.5" to cut a bevel in the head of the pins. https://i.imgur.com/qiBdVgih.jpg One of the pins on each arm were longer with a groove to mount the spring. I used the Delta carbide grinder with the table set to 7* to reshape an old/broken 60* threading bit to match the shape of the original groove. https://i.imgur.com/xoaLlLzh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Very nice..!!...
is that a die grinder burr bit chucked up in a mill? |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Quote:
|
| All times are GMT -4. The time now is 05:57 AM. |
Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.
Copyright 1997-2022 67-72chevytrucks.com