My '57 Truck Build "Rosa"

[57picupnewbie]

thanks guys! 67step, that frame should work fine. Post some pics. I am buying my plasma cutter so body work begins. Already started with the smothing of the firewall. MAN THERE IS ALOT OF HOLES....lol

[57picupnewbie]

Dropped in motor today for the first mock-up. I needed to check the firewall clearance for the distributor. Found out I have plenty of room thanks to the EZ Chassis Swap. Todd, at the school is having to cut his firewall back to allow room for his distributor. He did not go with the EZ Chassis Swap Kit. His cab sits lower. Now I can pull it back out and continue filling holes in the firewall.

[Kim57]

That color combo looks real nice.
Kim

[57picupnewbie]

Thanks Kim.

I have not been on in awhile but I wanted to update. I have been practicing welding since it is new to me. I bought the Eastwood 135. I like it due to really being able to contol the heat. I also, just ordered and got the plasma 110/220. I have learned a few things.

1. You cannot rush yourself when welding or grinding.

2. Grinding welds WILL make you a better welder.

3. Skip around and let cool.

Alot have said to work on one area at a time. Due to my lower back problems, I have three areas I am working. This allows me to stretch and have different positions. They are the holes in the firewall, the hood and the major part which is the driver's side step area. I have missed all you guys and hope to now be caught up and back on regularly.

[Kim57]

Looking good.
I hear you on the back problems. Just take it slow and steady and you'll get there.
Kim

[Russell Ashley]

Looks like it's coming along good, good to see you back at it. Keep the pics coming.

I have to wonder, did all PO's of TF trucks just like to make holes in the firewalls? It seems like the first thing most of us did when we started was to fill a bunch of extra firewall holes, LOL.

[_Ogre]

Originally Posted by 57picupnewbie

2. Grinding welds WILL make you a better welder.

definitely

i too have problems working low, i solve that by working on my cab raised 4 ft up
i had a forklift to work on but any platform would work

i see you use a die grinder for cutting, if you need something a little faster and aggressive
try using a 4'' electric grinder with 5'' cutting wheels. that all i ever use anymore
harbor freight sells grinders cheap, buy 2 they're real cheap
5'' cutoff wheels last 2-3 times longer than the 4'' wheels

[57picupnewbie]

Thanks Kim, we will do.

Russ, I do believe we all have either filled all those holes or just covered them. Man there is alot of them. I tell you, drilling spot welds just is no fun either. They sure had fun putting those in at the factory...lol

Orie, I do have a 4" grinder (electric) that I grind my welds with. I will have to give it a try. I just have more control with the die grinder in small tight spaces. It is nice to chat with all of you again. Thanks.

[55Cameo]

Very nice build going on here. Like the progress you have so far and the frame swap is coming out really nice

[Russell Ashley]

We haven't seen an update in a while. Anything going on?

[Russell Ashley]

No posts in three months. What's happening? I hope the back problem is not what stopped the progress.

[57picupnewbie]

Hey guys! I apologize for the absence. Down in the back some and also involved with my boys and their activities. My dad is also getting older and I have been spending some time with him. Spent too much time away while floating on the ocean with "Uncle Sam". I don't know how much longer I will have him around. Anyway, I am slowly getting back to the ole girl. I have the firewall holes welded up. Finishing up grinding. I have started fitting driver's step and rocker patch panel. I had posted pics previously. I will post new pics when I can. Hey Russ, thanks for asking. I have missed you guys. I have started reading back trying to catch up with all of your builds. Bam and Ogre your builds are awesome. Great work!

[72BLUZ]

slowly but surely it is taking shape!!!!!!!!!!!

[57picupnewbie]

Okay guys, time for an update. I cleaned my shop up and organized all my tools AGAIN last week. (Something about having a 7 year old and tools falling off the boards into floor...lol). Today, I finished massaging the lower hinge pocket panel. Hopefully, I can tack it tomorrow. I also, was able to remove the old, inner hinge pocket panel. Any of you guys that have replace these, should know that they are a B***H to get out and to get the repops fitted. I was able to get the area cleaned up fairly nice. I will take pictures tomorrow. It really feels nice to get back in the shop.

[57picupnewbie]

I know it has been a long time since you guys have heard from me. After "honey-dos", a new roof on the house, and a death in the family I think I am finally back on track. It really feels good to get back at it. I have been practicing my welding along the way which I needed desperately anyway since I am a beginner anyway.
I left off with the driver step removed and I was fitting the lower hinge pocket. I then discovered that the "Inner Step Panel" (there is no name for this because it is not reproduced) needed to be replaced due to being rusted some. Therefore, I had to go out on a limb and make one. This was new territory for me. It went better than I thought. Picture with the Yellow Arrow is the panel I am referring to. Here are the pictures for you guys.

[57picupnewbie]

After I finished this panel, I re-measured and test fitted the lower hinge pocket again. Everything was good so I tack welded it. We are making progress now.

[57picupnewbie]

I then moved around and marked and removed the Outer Hinge Pillar. The Inner Hinge Pillar was completely rusted out and missing (Go Figure)! After, Cutting and tweaking the reproduction Inner panel, I was able to get it to fit properly and ready to weld in. I check my fit for the outer panel one last time. Something told me to check the measurements on the Door Hinge Panel again. I am glad I did. WOW! Even with all the bracing, the cab corner had dropped on me 1/2". I only notice this after placing the step in to see what it would look like. One measurement was fine. However, Top door bolt to step measurement was off by the 1/2". Picture shows correction with jack bringing it back up to normal position. Now, I have a gap to fill in. I am just glad, I caught ii before I welded it all up. Fill you all in more in a few days.

[Kim57]

Looking good. Keep the pics coming.
Kim

[57picupnewbie]

Thanks Kim! It really feels good to be back at it.

Well, I went back out to address the 1/2" gap I was left with due to the cab corner dropping on me. So (pic 1) is what I was left to deal with. I did not like the idea of just welding in a patch due to this being a high stress area with the door weight and the weight of a person stepping out. So, I decided to make a back plate and spot weld it in first. This would add extra strength between upper and lower parts. See (pic 2). I then added in the 1/2" small patch and welded it up. End result is (pic 3). I think it turned out fairly nice for a novice. After, I get the inner and outer hinge pillar panels in that puppy is not going anywhere. I put the step back in place to check the fit and it is still on track (pic 4). It will not get tacked until I get the rear cab corners done.

Well, enough for tonight. I am tired and wife has steaks on the grill. You guys have a good night.

[Kim57]

That came out real nice.
Kim

[Russell Ashley]

Good to see you back, I've been wondering where you've been. The patch looks good.

[dubie]

i'm looking forward to seeing the front sheet metal on and seeing how the wheels fit inside the fenders

[_Ogre]

i like how you shaved the firewall but kept the original ridges.
did you think of shaving the standing seam on the firewall?

this



vs this?

[57picupnewbie]

Kim - Thanks, I was proud of it.

Russ - It is good to be back! After completing the patch, I felt like I had actually accomplished something.

Dubie - I will be glad to be at the point of having the firewall complete. Filling the holes was quite a learning experience in welding for me. I blew thru a lot of metal as I was learning. As for the wheels, well those may be awhile.

Ogre - My old friend! I was planning on a look like yours originally. Shaving the standing seam (due to mine being bent) and keeping the original ridges. However, Since, I have found a look that I just fell in love with. It is a sheet of polished stainless steel on the firewall that mirrors the engine. It would be awesome for car shows I think. I attached the picture for you guys to see.

[57picupnewbie]

Today, I spent almost 3 hours tweaking and adjusting the inner pocket panel. As you all know, not all reproduction parts fit "as advertised". I had to snip, and cut, and grind. I bent and hammered but it sits in there flat and smooth now. I finished welding it in and all is good. The only problem I have is my OCD is kicking in and I am having problems getting to the welds to dress them up. Now, I know these welds are going to be concealed and no one will ever see them. However, I know they are there. They may not be the most professional welds out there but they are mine and they will be the best that I can do. More tomorrow!