1966 F100 Short Bed Styleside Metal/Body/Paint Work

[theastronaut]

We were able to buy a Pullmax P7 since the last update. We had heard about a local Pullmax awhile back and had inquired about it but they weren't interested in selling it at the time. The owner contacted us a few weeks ago and said that they were ready to sell it so we made the deal and moved it to the shop. I'm looking into VFD's to run it at the moment, and have started cleaning it up. It came with a fence, circle cutting attachments, louver dies, center and offset tool holders, doming dies, nibbler dies, slotting dies, flanging dies, a beading die, and an offset flange dies, and a really neat dovetail extension that bolts to the side and swings out of the way when not in use. This will be a big help in allowing me to expand my metal fab capabilities.

[MP&C]

Nice score on the dovetail extension!! Don't see too many of them.. Quite a few dies too..

[mongocanfly]

Bed looks great John..!!..
Nice addition with the new tools..

[Russell Ashley]

I'm guessing that you didn't just pick that up and set it on the trailer, LOL. That looks heavy.

[theastronaut]

Originally Posted by MP&C

Nice score on the dovetail extension!! Don't see too many of them.. Quite a few dies too..

I couldn't find another with an extension like that with a quick google search. Wasn't sure if it was something they built themselves or if it was an actual Pullmax accessory.

Originally Posted by mongocanfly

Bed looks great John..!!..
Nice addition with the new tools..

Thanks!

Originally Posted by Russell Ashley

I'm guessing that you didn't just pick that up and set it on the trailer, LOL. That looks heavy.

It's a little under two tons. We lifted it up and bolted 8' skids to the feet, then used the winch to pull it onto the trailer. To get it in the shop I used a snatch block to pull it off the trailer, then a set of car casters to roll it into position. It was easier to move than expected.

[theastronaut]

Did some minor touch up and shot a few coats of Slick Sand.

[mongocanfly]

Wow...that looks flawless..

[MP&C]

Originally Posted by theastronaut

I couldn't find another with an extension like that with a quick google search. Wasn't sure if it was something they built themselves or if it was an actual Pullmax accessory.

Buddy of mine worked at somewhat local military base in their machine shop, they had a pullmax with the dovetail extension like that. He said they used it once for about 10' diameter disc they needed to make, other than that it wasn't used much in the 25+ years he was there..


Bed floor looks awesome.. looks like you picked up an NOS piece someplace..

[theastronaut]

Originally Posted by mongocanfly

Wow...that looks flawless..

Thanks! It's not quite flawless yet, there's always more sanding to do

Originally Posted by MP&C

Buddy of mine worked at somewhat local military base in their machine shop, they had a pullmax with the dovetail extension like that. He said they used it once for about 10' diameter disc they needed to make, other than that it wasn't used much in the 25+ years he was there..


Bed floor looks awesome.. looks like you picked up an NOS piece someplace..

Thanks Robert!



I made a block from three pieces of plexiglass that can flex to fit the sides of the ribs and flatten the bottom at the same time. All of the ribs are at slightly different heights so all of the sides are at different angles; I couldn't shape a durablock that fit all of the ribs like I did with the last F100, and it wasn't practical to make one durablock per rib.

Flexible Plexiglass Sanding Block - YouTube

[Russell Ashley]

I like how you always come up with a solution for every task. You got talent.

[theastronaut]

Getting deep into the details of the bed floor... The stamping details left a lot to be desired. The ends of the ribs were all different; the angle of the "ramp" was uneven from rib to rib and the radii of rounded edges were inconsistent. Having all of the surrounding surfaces blocked dead flat really makes this stand out, so I got out a foam sanding block and 180 to round everything over and sanded until the guide coat was gone so it wasn't as noticeable.



Just kidding! I scuffed up the ends, masked out the areas that were already blocked to the correct shape, then skim coated the ends to reshape them.



Inconsistent shape of the "ramp" part of the ribs.




Masked and scuffed with 180 to prep for filler.




One down.




I only did a couple at a time so I could do all the shaping while the filler was soft and sanded easily. This slightly clogs the paper so I use a brass brush to clear the out the stuck on filler. The tape on the end prevents the block from digging into the surrounding areas that are already flat and shaped correctly.










I used a longer block made from 1/2"x1/2" aluminum to block across a few ramps at a time so they're all at the same angle.




Final product- flat flats and sharp, even edges. I'll slightly round over the edges when I go 180 grit to smooth out the 80 grit scratches.

[ajgriffin]

Originally Posted by theastronaut

Getting deep into the details of the bed floor... The stamping details left a lot to be desired. The ends of the ribs were all different; the angle of the "ramp" was uneven from rib to rib and the radii of rounded edges were inconsistent. Having all of the surrounding surfaces blocked dead flat really makes this stand out, so I got out a foam sanding block and 180 to round everything over and sanded until the guide coat was gone so it wasn't as noticeable.

I think we all would have sent a search party to do a wellness check if that actually happened Great work as usual!

[theastronaut]

Filler hole details. The circle around the filler opening was sanded flat and level with the base of the floor between the ribs, but the transition from the flat circle to the rounded parts of the ribs needed truing up. I used a compass to establish a perfect circle for both the lower and upper edges of each rib, then filled and sanded until the sides of the ribs were the correct shape. It's hard to sand the inside of the corners to the correct shape though, so I pulled fine line tape and used a razor blade to shave the inside corners to the correct profile.

The end of the razor was taped to prevent that side from cutting what was already correctly shaped. The other end is up against the fine line tape; this shows how much the inside corner is off from only sanding.




After shaving down the raised corner all the way to the edge of the fine line tape.




Then the tape was flipped and the other half of the inside corner was shaved to the correct shape.




This left sharp angles at the transition between the straight edge of the ribs and the rounded edges around the filler neck.




Calipers used to establish a smooth transition shape.








Finished transition.

[mongocanfly]

John , your high level of detail always amazes me...very nice work...

[Ol Blue K20]

Amazing work and detail!!

[theastronaut]

Originally Posted by mongocanfly

John , your high level of detail always amazes me...very nice work...

Originally Posted by Ol Blue K20

Amazing work and detail!!

Thanks guys! After all the tedious sanding I'm ready to get started on the cab and do something different for awhile If the forecast is right I'll have better weather starting the middle of next week and can get the cab blasted.

[67C10Step]

That thing is gonna be so slick a mosquito couldn't land on it without sliding off!

Great work all the way around. Can't wait to see the final product.

[Russell Ashley]

You notice things so small that most of us wouldn't even see.

[Ol Blue K20]

Originally Posted by Russell Ashley

You notice things so small that most of us wouldn't even see.

I agree, the attention to detail is amazing!!

[theastronaut]

Originally Posted by 67C10Step

That thing is gonna be so slick a mosquito couldn't land on it without sliding off!

Great work all the way around. Can't wait to see the final product.

Originally Posted by Russell Ashley

You notice things so small that most of us wouldn't even see.

Originally Posted by Ol Blue K20

I agree, the attention to detail is amazing!!

Thanks guys!


I started the metal modifications on the dash. There will be an air vent taking the place of the original ignition switch, so the switch needs to be moved over below the gauge cluster. The AC controls will be on the right side under the cluster so the original holes need to be filled in.








This side needs three 9/32" holes so I'll weld in a solid panel and redrill new holes.










I made a new switch opening on a larger panel for less welding. I haven't decided if I want to try to press the new panel with the same indentions as the old switch holes or if I'll just graft them in, it'll probably be faster to just graft the existing pieces.






The speaker grill conveniently had round holes stamped in the corners which let me use a hole saw to make round corners for the new panel being welded in. Round edges on patch panels keeps the panel from having concentrated shrinkage on the weld seam in two directions like a 90* corner has so it's easier to planish out the weld seam later.






The dash was low on one side of the opening compared to the shape across the rest of the dash, so that was reshaped before welding in the new panel.


Correct shape-




Low side:




Straightened:




New panel made slightly oversized, then clamped in place to scribe the trim line.






Minimal gaps.






After grinding and initial planishing.

[mongocanfly]

Very nice John...
How did you go about fixing the low side of the dash?

[MP&C]

Beautiful work John!

[theastronaut]

Originally Posted by mongocanfly

Very nice John...
How did you go about fixing the low side of the dash?

Thanks! I used a hammer and dolly to stretch the metal up to the correct shape.

Originally Posted by MP&C

Beautiful work John!

Thanks Robert!

[Russell Ashley]

I think you are magic. How do you have time to do stuff like this and work on your Fiesta too?

[mongocanfly]

Thanks John...so to raise the panel , did you hold the dolley on the bottom side pushing up, and hammer on the top?..I've had some similar stuff I've worked my butt off trying to fix, so I had to ask...