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1966 F100 Short Bed Styleside Metal/Body/Paint Work
I just started another '66 F100 short bed project at the shop, this time it'll be a mild custom. I'll only be doing the metal, body, and paint work instead of a full build like the last one ('66 F100 Stock Restoration).
I'll be fixing the rust, correcting the panel fit and gaps like the last truck, shaving some items on the dash, mocking up a Vintage Air evaporator, smoothing the firewall, adding spots for A/C vents, and painting the truck. Here is the truck. It seems to be pretty solid overall other than the bed floor and door bottoms; definitely better than the other truck we restored. https://i.imgur.com/8rrwEUEh.jpg https://i.imgur.com/FEV9ApOh.jpg https://i.imgur.com/VuscNUFh.jpg https://i.imgur.com/0BVhtyBh.jpg https://i.imgur.com/aFlkaxVh.jpg https://i.imgur.com/ATwx7wMh.jpg https://i.imgur.com/OknQI7gh.jpg https://i.imgur.com/38GoCMEh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Panel fitment and gaps.
https://i.imgur.com/r99QgCPh.jpg https://i.imgur.com/tBv9SbSh.jpg https://i.imgur.com/SCJWJYGh.jpg https://i.imgur.com/vJ8C0smh.jpg https://i.imgur.com/juQLm6kh.jpg https://i.imgur.com/74Kl4c2h.jpg https://i.imgur.com/5VQQoYRh.jpg https://i.imgur.com/MKkapIQh.jpg https://i.imgur.com/U0Rb3hgh.jpg https://i.imgur.com/66W1yc7h.jpg https://i.imgur.com/rWQy0r9h.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
First update. I took everything apart that wasn't needed to make it run. All of the small parts were bagged and labeled so reassembly will be easier. I'll drive it around to one of the rear shop stalls tomorrow and finish dissasembly.
https://i.imgur.com/JoBpN1Hh.jpg https://i.imgur.com/9odGa0mh.jpg https://i.imgur.com/AhtiNTzh.jpg https://i.imgur.com/PCY6OOLh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Looks like it'll be another good when you get done....
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I am not a Ford guy in any stretch but....I prefer a truck like this one over the unibodies, they just look better imo!
FYI, favorite Ford truck is the 67 short bed |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Looking forward to the perfection that's coming. 👍
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Teardown is finished. I'll finish removing the seam sealer and start blasting pieces next week.
https://i.imgur.com/tQvqoTYh.jpg https://i.imgur.com/wxRJGich.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
That should keep you busy for a little bit.. Subscribed!
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Your projects are always interesting, and beautiful. I've been waiting for you to start another one. I hope you document this one like you did the first 66 Ford.
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Cool truck. That's a great body style. I had a 62 Unibody.
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I have the bed floor and header panel out now, and have blasted around the peremeter to prepare for welding the new floor in. A 2008 Super Duty floor is the same dimensions so we ordered one to use, along with a new header panel and front sill from Carolina Classics. The rear sill isn't available so I'll have to repair and straighten it. https://i.imgur.com/MvgNpl4h.jpg https://i.imgur.com/s7u7zc2h.jpg The seam sealer was difficut to remove by blasting so I used a dremel to cut it out. https://i.imgur.com/fSi2OMth.jpg New floor and header. https://i.imgur.com/niO0jrOh.jpg https://i.imgur.com/eVOE2Hoh.jpg Edges blasted to prep for repair work and new panels. https://i.imgur.com/BzD4PRrh.jpg https://i.imgur.com/p7vegKSh.jpg https://i.imgur.com/MxgwKXJh.jpg https://i.imgur.com/01Xre6Kh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
The four corner panels were all bent and sunk in so I started straightening those this morning. This was the driver side rear panel.
https://i.imgur.com/Ut0Errdh.jpg https://i.imgur.com/dUEokRih.jpg https://i.imgur.com/eOx7h5qh.jpg I started with the flange, then used a socket and hammer to shrink the panel back flat. The socket "traps" the metal and lets the hammer push the metal into itself, shrinking the panel. The socket has to be bigger than the hammer head and you have to keep the hammer in the dead center of the socket or else you'll hit against the edge of the socket and stretch the metal. MP&C has info on this in his '55 Wagon thread. https://i.imgur.com/X6eI1Och.jpg https://i.imgur.com/EiQBqaDh.jpg https://i.imgur.com/29as2NVh.jpg https://i.imgur.com/pEqSJzQh.jpg https://i.imgur.com/cRtkpl5h.jpg https://i.imgur.com/niwaoSkh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Driver side front panel.
https://i.imgur.com/Se8xUCoh.jpg https://i.imgur.com/5L9b9shh.jpg https://i.imgur.com/PMxB3oVh.jpg After: https://i.imgur.com/mD5pCWch.jpg https://i.imgur.com/mbnT4ikh.jpg https://i.imgur.com/5OSeczbh.jpg https://i.imgur.com/NpO2Pnmh.jpg I also made and fitted both front corners that were rusted. https://i.imgur.com/jSM3ZEVh.jpg https://i.imgur.com/flgQeOeh.jpg Blasted and shot SPI epoxy on the two floor braces. https://i.imgur.com/0H3j4Mzh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Awesome work John!
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
You make that look easy John....good work..
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The inside of all the panels were shot with undercoating so I scraped all of it off to prep for blasting. https://i.imgur.com/u7iqLj5h.jpg https://i.imgur.com/hQkpyn8h.jpg https://i.imgur.com/tYbGYBbh.jpg After: https://i.imgur.com/Kj8uDC9h.jpg https://i.imgur.com/wWvZAVsh.jpg https://i.imgur.com/2SS4rrph.jpg The two center floor braces were bent so I used our tubing roller to straighten them. https://i.imgur.com/X0tRg7nh.jpg https://i.imgur.com/76bfuGsh.jpg They were also dented around the mounting bolt holes. https://i.imgur.com/K09OQTGh.jpg The truck was stripped and repainted at some time. The paint strips easily and quickly with a razor blade leaving a thin coat of primer and some spots of filler. I'll strip the primer/filler with a DA sander to avoid blasting and warping the bed sides. https://i.imgur.com/Sg0Cg2Zh.jpg https://i.imgur.com/7VetBUVh.jpg I test fit the front header and cross brace, the filler panels I made, and the center braces. https://i.imgur.com/PWXEoRHh.jpg https://i.imgur.com/C5TOndTh.jpg https://i.imgur.com/jWxY59Nh.jpg https://i.imgur.com/bAvYnkCh.jpg https://i.imgur.com/cB5y07Mh.jpg https://i.imgur.com/LQ5NdbSh.jpg Also cut out the rust that was on the flange that the bed floor spot welds to and welded in new metal. https://i.imgur.com/YbOVdxrh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Subbed......I like watching your projects.
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Yup, this is going to be awesome.
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Thanks for following! I've been working on blasting the bed, inside and out and underneath, that's about 95% done. I'll work on straightening and repairing as much as I can while it's in bare metal before going back over the areas I missed with the blaster and then shooting epoxy. The seam between the upper and lower passenger side bedsides was pretty rough so I spent extra time cleaning it out with the blaster. https://i.imgur.com/N2ntwRth.jpg https://i.imgur.com/QJNcxgvh.jpg The new F250 bed floor has stamping for a fifth wheel ball, and the owner wants to add a fuel tank under the bed with the filler cap in the bed floor. I'll cut out two sections and swap them to make the center smooth and have a stamped area around the filler cap. https://i.imgur.com/Jd2Ot3eh.jpg The rear corners had back up lights added, so I straightened the area and welded up the holes. https://i.imgur.com/x4GjXbAh.jpg https://i.imgur.com/8J2pFvph.jpg https://i.imgur.com/bhDdccxh.jpg The bedside is wavy and sunk in over the front of the wheelwell so I've started stretching the area by hammer-on dolly plannishing the area to raise the low spots. https://i.imgur.com/Lu1yY1jh.jpg The bottom driver side behind the wheel opening had a couple creases, dents, and a torn spot on the edge of the flange. https://i.imgur.com/iKXbfeEh.jpg https://i.imgur.com/QdSHO44h.jpg https://i.imgur.com/5Avb2XRh.jpg https://i.imgur.com/N3HiGQ6h.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
looking good with the rapairs...great idea for the fuel fill switcharoo...
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I always look forward to your updates. Always very interesting, and I like your before and after shots. I had a 65 Ford like this with the available trim, bright grill, bumpers, etc. Has the owner of this one indicated that he would like you to add this to this one? I think it's all available.
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I had seen people use Bronco wheel tubs to widen the factory tubs, and to use for trucks with raised bed floors but not for stock tub replacement so I wasn't sure that they'd work. They were only $70 shipped each so we bought one to try out and the stamping ended up being identical with only a couple details that needed attention.
The stock tubs were pretty rough so I cut them out with the plasma to get to the inner flange. https://i.imgur.com/X8AVLKkh.jpg https://i.imgur.com/n30e0kVh.jpg For Bronco applications they had a notch cut out for the shock mount. I welded that up since the bed floor will be welded to that area of the flange. https://i.imgur.com/5ZmMcPDh.jpg Test fit. https://i.imgur.com/IrSLTsQh.jpg https://i.imgur.com/EPI1RULh.jpg Trimming the bottom edge to match the original shape. https://i.imgur.com/czY5TjDh.jpg https://i.imgur.com/lfhdSYih.jpg Couple of pinholes welded up. https://i.imgur.com/Al5fWauh.jpg https://i.imgur.com/j2EGW48h.jpg https://i.imgur.com/MdsHatRh.jpg https://i.imgur.com/9JXkUWgh.jpg There were dimples in the flange area from the original spot welds so I straightened those so the new tubs would fit flush. https://i.imgur.com/fZU2bBOh.jpg https://i.imgur.com/FCfplYjh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
The driver side bed corner fit pretty well at the bottom but stuck out past the bedside towards the top.
https://i.imgur.com/DXhHZJUh.jpg https://i.imgur.com/Ikb1tLFh.jpg I was able to reach the spot welds through the taillight opening with an extended nose grinder and carbide burr. You can see how much I moved the panel inward to make the two flanges flush. https://i.imgur.com/c5Ruz7Ph.jpg https://i.imgur.com/Sw02iTXh.jpg We decided to shave the stake pockets, so I cut out the flanged lip and made a filler panel that keeps and extends the seam so it looks like a factory panel. https://i.imgur.com/tJVrPsgh.jpg https://i.imgur.com/ba1u95eh.jpg https://i.imgur.com/OGuLstgh.jpg https://i.imgur.com/RWiZmSXh.jpg I drilled a couple holes to plug weld the filler panel's flange in place like the rest of the corner's flange. https://i.imgur.com/IkDOiJlh.jpg Coated the inside of the corner with epoxy before welding it shut. https://i.imgur.com/C3w9gKkh.jpg Finished. https://i.imgur.com/DdnL5xlh.jpg https://i.imgur.com/NB6KcP3h.jpg https://i.imgur.com/HaTAyvxh.jpg https://i.imgur.com/RfO6U7Qh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
That stake pocket cap and wheel tubs looks great!...
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
It's looking great. You make it look so easy!
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Work looks great as always.
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You notice details that are so small that some of us would never notice they need fixing.
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Very nice work on the ole girl!
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Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Thanks guys!!
The passenger side pocket was a bit more work since the seam was crooked at the top. I rounded off an air chisel tip and used that to move the edge of the long panel over to where it should've been. https://i.imgur.com/L34zoRUh.jpg https://i.imgur.com/tBLqQZdh.jpg After moving it over, still not perfect but much better than before. https://i.imgur.com/bwkNLPuh.jpg Patch made, determining the right spot to make the bend so the gap is even. https://i.imgur.com/0r9avhFh.jpg Bent, fitted, and welded weld in. https://i.imgur.com/LDEsaXhh.jpg https://i.imgur.com/tiRgyxXh.jpg The front bed pockets were opened up to get back to flat metal, then were straightened, spot blasted to touch up missed areas of rust, primed, and welded shut. https://i.imgur.com/rxKCEaeh.jpg https://i.imgur.com/Bcqd2Noh.jpg https://i.imgur.com/FawUNWfh.jpg https://i.imgur.com/aqC5fabh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
The second wheelwell came in so I started getting it ready to install. The shock notch was welded up first, then I had to narrow the mounting flange to clear the raised lip on the inner bedside.
I scribed a line on the patch, then trimmed with tin snips for a near-exact fit with no grinding needed. This saves grinding discs and makes less dust in the shop. https://i.imgur.com/pSAOOWxh.jpg https://i.imgur.com/QKBxIkWh.jpg https://i.imgur.com/1sbeHUSh.jpg https://i.imgur.com/8izL0Udh.jpg Difference in flange width. https://i.imgur.com/xsT90ybh.jpg https://i.imgur.com/hZF8gzth.jpg https://i.imgur.com/2Ehxq08h.jpg https://i.imgur.com/LysYgzbh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
I welded in the header panel using the original spot weld holes, but some of those were halfway off the edge of the panel so I used a copper spoon to keep the weld contained and the edge straight.
https://i.imgur.com/XRoxyJnh.jpg https://i.imgur.com/CQmxCIhh.jpg The upper seams weren't pretty from the factory and they won't really be seen once the truck is assembled. I welded them up and ground down the welds so that all of it would look decent once seam sealer is applied. https://i.imgur.com/V1H43oyh.jpg https://i.imgur.com/cZtV6bLh.jpg https://i.imgur.com/cwiKkjNh.jpg https://i.imgur.com/tYMAQwKh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Outstanding!!!....I'm jealous of your skills and how well your making that metal look....
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I''ve made a bit more progress, just haven't been posting. The hood, doors, and fenders are all stripped now. One fender is trashed too bad to fix, the other is in pretty good shape, both doors are pretty straight with the normal rust at the bottom edge, and the hood is really nice except the edge of the nose.
https://i.imgur.com/RpTkKvZh.jpg https://i.imgur.com/ahyXRneh.jpg https://i.imgur.com/TSMUcJih.jpg https://i.imgur.com/brg1sZph.jpg https://i.imgur.com/QXCuSpph.jpg https://i.imgur.com/gBc6yo2h.jpg I also started the bodywork on the upper part of the bedsides. I'll wait to do the lower section once the bed floor is welded back in, it's too flimsy as-is. I always block the "flat" sections first, first the top and then the side, leaving the rolled area for last. The flats need to be established first before rounding the curved area. I stopped blocking as soon as I saw epoxy showing through, continuing to block will result in low spots. https://i.imgur.com/IL0in8Ch.jpg https://i.imgur.com/IL0in8Ch.jpg Once the flats are blocked straight I spray more guide coat on the flat areas then carefully block the curved section until it blends evenly into the flat areas. The guide coat shows how far you're blending the curve into the flats. https://i.imgur.com/NoTN4lth.jpg https://i.imgur.com/ZX3Lhd2h.jpg https://i.imgur.com/kJ7EIGUh.jpg All work up to this point is done with 80 grit on a 3/8" thick acrylic sanding block. The acrylic has a hard surface force the sandpaper to cut the high areas down quickly and 3/8" is stiff enough to not flex. 80 grit is aggressive enough to shape the surface without leaving excessively deep scratches. Once everything is shaped with 80 grit I clean the surface well and apply more guide coat, then block it again with 180 to prep for primer. This round of blocking will show if you blended the curves into the flats evenly. https://i.imgur.com/oBnW9Ebh.jpg https://i.imgur.com/UjgYoz8h.jpg https://i.imgur.com/NwWRb7Mh.jpg After spraying a couple coats of epoxy to seal the bodywork. You can see how straight the flats are, how crisp the edges are, and how evenly the curved areas blend into the flat areas. This will be further refined with polyester high build. https://i.imgur.com/QNwJnpOh.jpg https://i.imgur.com/pd1GXnhh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Same process with polyester primer. Flats first, more guide coat, then curves blended into the flats.
https://i.imgur.com/NpKPsLYh.jpg https://i.imgur.com/aPh8dVdh.jpg https://i.imgur.com/m1To5bJh.jpg Same approach with the rear corner, except with thinner/flexible acrylic blocks. https://i.imgur.com/pdLMHVph.jpg https://i.imgur.com/eEcPFSHh.jpg https://i.imgur.com/qTCMA1hh.jpg https://i.imgur.com/DptzxFNh.jpg |
Re: 1966 F100 Short Bed Styleside Metal/Body/Paint Work
Looking good, your attention to detail is amazing. I also learn a lot keep it coming.
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