Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Amazing work, you never disappoint!

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

WOW great resto!

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Thanks guys!!


We converted the oil bath on the '66 to a paper filter using a universal 9" round Mr Gasket air cleaner. The height is perfect to keep the outer lid in the right position. No need to fabricate or weld in upper/lower plates to seal the filter or hunt around for the right filter. The original fiber filter was falling apart so we didn't want any of it getting it in the engine. Also didn't want it backfiring and puking oil all over the detailed engine!


Uncrimped the inner flange and cut the "spokes" around the edges to remove the old filter material that was disintegrating.

http://i557.photobucket.com/albums/s...90651065_n.jpg


I still need to remove the inner ring on the original lid for more filter clearance.

http://i557.photobucket.com/albums/s...52648327_n.jpg


The new air filter base fits perfectly over the original base. I will drill ~1" holes around the perimeter of the original base for easier air intake.

http://i557.photobucket.com/albums/s...12414194_n.jpg

http://i557.photobucket.com/albums/s...44969903_n.jpg

http://i557.photobucket.com/albums/s...26005761_n.jpg

http://i557.photobucket.com/albums/s...44068589_n.jpg


Just enough of the stud sticks through for the wingnut.

http://i557.photobucket.com/albums/s...30370696_n.jpg

http://i557.photobucket.com/albums/s...12073557_n.jpg


Finished up the mods on the air cleaner- drilling holes in the base for better air flow and cutting out the inner ring of the lid to clear the new inner filter. Then blasted and primed it with DPLF epoxy.

http://i557.photobucket.com/albums/s...64944547_n.jpg


The new fuel lines came in so they're installed with new stainless clamps.

http://i557.photobucket.com/albums/s...08031847_n.jpg

http://i557.photobucket.com/albums/s...71980550_n.jpg

http://i557.photobucket.com/albums/s...03041235_n.jpg

http://i557.photobucket.com/albums/s...41294662_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Very nice work!! Great attention to details that many will never even see
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Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Thanks hopped up!!


Just painted/detailed the tie rods.

http://i557.photobucket.com/albums/s...61682081_n.jpg


Cleaned the boots with 3M adhesive remover to clean the mold release wax off, then applied Duragloss Rubber and Vinyl Dressing, before and after.

http://i557.photobucket.com/albums/s...74858688_n.jpg


http://i557.photobucket.com/albums/s...19230331_n.jpg

http://i557.photobucket.com/albums/s...06407471_n.jpg

http://i557.photobucket.com/albums/s...92074095_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Air filter lid was sprayed with epoxy, minor dings filled and blocked flat, shot with high build, then flat areas blocked with 180, then wetsanded with 600. I sprayed it with the same single stage urethane we've been using, but added 25% flattener instead of the usual 33%.

http://i557.photobucket.com/albums/s...20055062_n.jpg

http://i557.photobucket.com/albums/s...04330633_n.jpg

http://i557.photobucket.com/albums/s...54546665_n.jpg

http://i557.photobucket.com/albums/s...93557037_n.jpg

http://i557.photobucket.com/albums/s...76309460_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

You sir are the man..
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Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Thanks Chad! I know you'll appreciate the next update... I wetsanded/buffed the air filter lid, didn't like the slightly dull finish.

http://i557.photobucket.com/albums/s...77328575_n.jpg

http://i557.photobucket.com/albums/s...29686818_n.jpg

http://i557.photobucket.com/albums/s...69517853_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Again.........Speechless.

Top notch work, John!

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Killer work!
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Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Thanks dudes!!


Stuck the repop decal on the lid. Can't wait to get the carb back from being rebuilt/restored so we can install it and the filter back on the engine.

http://i557.photobucket.com/albums/s...28510709_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

The carb came back today and it looks great! Also picked up some NOS clamps for the heater hoses and water pump bypass.

http://i1315.photobucket.com/albums/...05812889_n.jpg

http://i1315.photobucket.com/albums/...31847852_n.jpg


Chucked the clamps in the bead blaster and lightly went over them to brighten them up a bit.

http://i1315.photobucket.com/albums/...37431800_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Carb, spacer, and filter in place.

http://i1315.photobucket.com/albums/...16276150_n.jpg

http://i1315.photobucket.com/albums/...42549014_n.jpg

http://i1315.photobucket.com/albums/...70034117_n.jpg

http://i1315.photobucket.com/albums/...89356778_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

WOW, I am amazed with your work.

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

He only has one speed PERFECTION

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

That is AMAZING work!

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Thanks dudes!!! :)



I forgot to post these the other day, so here they are.


We cut out the floor pans and started trimming the new ones to fit. The don't fit well and they're missing the upper outside edges so we'll have to make those and weld them on. The inner rockers are mostly good except for the very front area where the hinge pillar meets up and overlaps. Whoever designed the way the cab metal assembles was an idiot... and further cements the reasons why I'm a Chevy guy ;)

http://i1315.photobucket.com/albums/...80270151_n.jpg


Screwed in over the original pans to mark the trim lines.

http://i1315.photobucket.com/albums/...45460001_n.jpg


Cutting the floors out.

http://i1315.photobucket.com/albums/...20573328_n.jpg


Making a template for the seat risor area.

http://i1315.photobucket.com/albums/...47711242_n.jpg


Right side inner kick panel rust. This area is a PAIN to work around, and the layers of sandwiched metal layers is impossible to fix without tearing out good metal around it.

http://i1315.photobucket.com/albums/...98351454_n.jpg


Upper kick panel edge along the toe boards.

http://i1315.photobucket.com/albums/...05914102_n.jpg


The floor flange that welds to the kick panel underneath the truck, this was missing completely on the new pans... :-roll

http://i1315.photobucket.com/albums/...70262382_n.jpg

http://i1315.photobucket.com/albums/...30272443_n.jpg


The cab mount plates are solid.

http://i1315.photobucket.com/albums/...17074731_n.jpg


Lower kick panel edge from the outside.

http://i1315.photobucket.com/albums/...73035574_n.jpg


Drilled the spot welds...

http://i1315.photobucket.com/albums/...31063750_n.jpg


Making the new floor pan flange to weld to the kick panel.

http://i1315.photobucket.com/albums/...97053230_n.jpg


The inner rocker rust.

http://i1315.photobucket.com/albums/..._1003415_n.jpg


Starting to drill the spot welds and separate the inner rocker from the other layered panels.

http://i1315.photobucket.com/albums/...31913512_n.jpg

http://i1315.photobucket.com/albums/...41321446_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Started back on the right side rust repair today, got everything cut out and a couple pieces ready to weld back in.

Started by drilling the spot welds. These weren't welded to anything though...:crazy:

http://i1315.photobucket.com/albums/...43200373_n.jpg


Separating the layers.

http://i1315.photobucket.com/albums/...91737597_n.jpg


Inner rocker out, exposing whats left of the kick panel layer.

http://i1315.photobucket.com/albums/...40291908_n.jpg


Inside half of the inner rocker.

http://i1315.photobucket.com/albums/...01582884_n.jpg


Making a paper template to fix the rusted spot.

http://i1315.photobucket.com/albums/...18000401_n.jpg


Template transfered to metal, and I rolled a bead along the spot what will be the edge once its bent.

http://i1315.photobucket.com/albums/...87159440_n.jpg


Bending the edge in the metal brake.

http://i1315.photobucket.com/albums/...12218274_n.jpg


Edge detail.

http://i1315.photobucket.com/albums/...17040224_n.jpg


Front edge folded up straight like the original piece.

http://i1315.photobucket.com/albums/...37344327_n.jpg


Both pieces bead blasted, marking the original for cutting.

http://i1315.photobucket.com/albums/...03381261_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Marked the lower cowl for cutting.

http://i1315.photobucket.com/albums/...02580427_n.jpg


More hidden rust.

http://i1315.photobucket.com/albums/...64673229_n.jpg


Cutting out the kick panel.

http://i1315.photobucket.com/albums/...50920721_n.jpg


Floors, inner rocker, and kick panel rust completely cut out.

http://i1315.photobucket.com/albums/...13132226_n.jpg


Ready for sandblasting, priming, and fitting/welding the new panels.

http://i1315.photobucket.com/albums/...67859642_n.jpg


Fabbed and fitted the rear floor panel.

http://i1315.photobucket.com/albums/...29687903_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Amazing work for sure... Keep up the good work your builds are always so informative..

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Wow, I'm thinking there's not a truck too far gone for you to bring back. Those look like complicated pieces to make with all those multiple bends and angles. I would love to be able to make panels like that.

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

That is a ton of work and a bunch of rust. Your work is top notch. I wish you were closer, I could have you do my cab for me...Oh Well, guess I'll have to learn from your work and pictures here...

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Thanks Frenchblue!!


Thanks plainred, but we have limited tools and I'm still learning. But compared to many, this amount of rust is mild... very mild! Take a look over on thesamba.com in the Barndoor Bus section and have a look at what those guys are saving... :eek: That basket of green patch panels are just a little bit of the patch panels going into this bus... 10k worth of patch panels isn't unheard of in the Barndoor bus world!!

Here's the build thread.

http://www.thesamba.com/vw/forum/viewtopic.php?t=471779

http://i557.photobucket.com/albums/s...m/d8baf98e.jpg

http://i557.photobucket.com/albums/s...m/dd48dad5.jpg

http://i557.photobucket.com/albums/s...m/4e525c59.jpg


Thanks Karl, yall are doing a great job on your son's truck!!

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

Made the passenger side kick panel today. Had a couple beads to roll in it and I had to form a curved 90* flange on one edge.

http://i1315.photobucket.com/albums/...98461468_n.jpg

http://i1315.photobucket.com/albums/...46800627_n.jpg

http://i1315.photobucket.com/albums/...94947467_n.jpg

http://i1315.photobucket.com/albums/...12228478_n.jpg


I started comparing the original inner kick panel on the driver side to the patch I made yesterday, and there were differences that I didn't catch. The passenger side was rusted away badly and the template I made from that didn't carry over the original shape well enough. So I made a new template from the driver side and made two new pieces, L&R.


This shows the curved top flange that I made straight on yesterday's piece.

http://i1315.photobucket.com/albums/...61835617_n.jpg


Making the top flanges.

http://i1315.photobucket.com/albums/...89644096_n.jpg


Rolled a bead on the edge.

http://i1315.photobucket.com/albums/...74529767_n.jpg


Welding the flange to the new inner rocker patch.

http://i1315.photobucket.com/albums/...91727968_n.jpg

http://i1315.photobucket.com/albums/...88453131_n.jpg

http://i1315.photobucket.com/albums/...90151882_n.jpg


Smoothing the welds with a 2" grinder, being careful not to lose the details of the rolled edge.

http://i1315.photobucket.com/albums/...92489935_n.jpg


Sanded with the DA to smooth the grinding marks.

http://i1315.photobucket.com/albums/...09744490_n.jpg


Panel for the other side.

http://i1315.photobucket.com/albums/...03276056_n.jpg

Re: 1966 F100 Short/Fleen Full Stock Resto Build Thread
 

I agree 1000%. If you compare a Chevy/GMC cab to a comparable year Ford, there's no comparison. Ford likes to single-wall in places that GM will double wall. The GM cabs are WAY stronger structurally. The make-up of the Ford cab is such that it was like it was built backwards. The overlays are completely backwards, like you unfortunately discovered. You wind up damaging good metal on top in order to fix the bad metal underneath because the wrong part is flanged and spot-welded in an area that's completely inaccessable.

I know most guys are brand loyal, done to the bone. I have had the "discussion" with the Ford guys about the comparison of the '60s Ford and Chevy trucks, and have laid out all the differences. EVERY aspect of the Chevy is better, from the suspension, the engine, the transmission, and the body structure. I will give Ford credit in one area, though. Whoever designed their door latches did a great job. You can go to any clapped out Ford in the wrecking yard, and the doors close and latch soooo nice.

Other than that, their trucks are not even close.