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

I would say I hope that the owner is aware of your attention to detail but I'm sure they already know, that's why they have you restoring there truck.

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

They come by and check on it often, and we upload all of the pictures to our shop's facebook page so they can see all the details there. They've seen the '65 C10 and the '55 International, and also a buddies Jeep that I helped do the body/paint on.

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

Where's the link to the pics of the jeep.

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

I didn't do a build thread for it, it was just a "quick paint job" doing all the bodywork/prep in my buddies garage... ;) Spent a ton of time with a sledge hammer, 2x4s, and a porta-power getting all the inner braces in line so the outer sheetmetal could be straight. We used flattener in the clear for a matte look- most nervous I've ever been when spraying! One mistake and you let it dry, wetsand, and start over.


Here's what few pics I have of it.


http://i557.photobucket.com/albums/s...0F51C040BD.jpg

http://i557.photobucket.com/albums/s...78F561FF46.jpg

http://i557.photobucket.com/albums/s...78B869C47C.jpg

http://i557.photobucket.com/albums/s...78B869C47C.jpg

http://i557.photobucket.com/albums/s...789A5B5CB2.jpg

http://i557.photobucket.com/albums/s...7859BE5DB9.jpg

http://i557.photobucket.com/albums/s...791C61C8A8.jpg

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

I tore down the cluster after lunch and started restoring it. Need to find a speedometer or a speedo needle since the original needle is broken.


http://i1315.photobucket.com/albums/...59958489_n.jpg

http://i1315.photobucket.com/albums/...54075637_n.jpg

http://i1315.photobucket.com/albums/...62490625_n.jpg

http://i1315.photobucket.com/albums/...31137069_n.jpg

http://i1315.photobucket.com/albums/...58582255_n.jpg

http://i1315.photobucket.com/albums/...31962980_n.jpg



Used florescent red paint on the needles.

http://i1315.photobucket.com/albums/...92481283_n.jpg

http://i1315.photobucket.com/albums/...63085668_n.jpg

http://i1315.photobucket.com/albums/...63283329_n.jpg



Cut up translucent red sheets from Hobby Lobby to use as warning light lenses. I stacked four pieces together to make them dark enough. The outside piece that goes against the background plate was sanded with 2500 grit to knock the shine off and look more like the original dull lens.

http://i1315.photobucket.com/albums/...90785877_n.jpg

http://i1315.photobucket.com/albums/...29516568_n.jpg

http://i1315.photobucket.com/albums/...14929046_n.jpg

http://i1315.photobucket.com/albums/...58754108_n.jpg


Holding it up to the shop lights.

http://i1315.photobucket.com/albums/...21182331_n.jpg



Test fitting the new bezel, lens, and background piece.

http://i1315.photobucket.com/albums/...66486396_n.jpg


Prepped the gauge faces by lightly sanding to remove any roughness or oxidized paint, then cleaned them and used a tack rag to remove dust before applying the overlay.

http://i1315.photobucket.com/albums/...39456723_n.jpg



Used a heat gun to make the vinyl stretch around the raised lettering on the gauge face, and a microfiber towel to help push the decal around the stampings.

http://i1315.photobucket.com/albums/...43571197_n.jpg

http://i1315.photobucket.com/albums/...48789045_n.jpg

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

:thumbs::thumbs: on the cluster, nice plug on the glass shop.

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

Thanks James! We have those notepads everywhere, had to do something with it!

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

Another spot on the bedside flange that needed repair. Lots of splits/cracks.

http://i1315.photobucket.com/albums/...00510068_n.jpg


After welding/grinding.

http://i1315.photobucket.com/albums/...02108914_n.jpg

http://i1315.photobucket.com/albums/...63318392_n.jpg


Checking the fit of the bed corner flange.

http://i1315.photobucket.com/albums/...87429665_n.jpg

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

I'll bet that gauge cluster was a nice break from the bodywork. Looks great!

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

That's exactly why I was working on the gauge cluster.. :lol:

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

I finished the cluster today. Here's how the speedo decal went. Lining up the lines with the raised ridges was the first step after cleaning the face.

http://i1315.photobucket.com/albums/...62188782_n.jpg


Working from the center out.
http://i1315.photobucket.com/albums/...55398211_n.jpg


Keeping the edges pulled tight to keep wrinkles out.

http://i1315.photobucket.com/albums/...70011566_n.jpg


Right side finished. Amazing how well the printed lines line up with the stamped lines, Jason got this right!

http://i1315.photobucket.com/albums/...41033412_n.jpg

http://i1315.photobucket.com/albums/...58625803_n.jpg


Speedo finished. Odometer cleaned, reset to zero and needle repainted.

http://i1315.photobucket.com/albums/...24009123_n.jpg


Housing bead blasted inside and out. Outside was shot with satin clear to preserve the zinc plating, and the inside was repainted with white.

http://i1315.photobucket.com/albums/...94495799_n.jpg

http://i1315.photobucket.com/albums/...04047148_n.jpg

http://i1315.photobucket.com/albums/...35746650_n.jpg


Masked out to repaint the two black areas.

http://i1315.photobucket.com/albums/...42858360_n.jpg

http://i1315.photobucket.com/albums/...03241511_n.jpg


Starting reassembly .

http://i1315.photobucket.com/albums/...68288710_n.jpg


Making new bumpers for the lens edges.

http://i1315.photobucket.com/albums/...15632257_n.jpg


Used 3M strip caulk to seal the edges of the light tubes.

http://i1315.photobucket.com/albums/...85385450_n.jpg

http://i1315.photobucket.com/albums/...19227582_n.jpg


Background plate and lens installed.

http://i1315.photobucket.com/albums/...21501112_n.jpg


And finished.

http://i1315.photobucket.com/albums/...18026284_n.jpg

http://i1315.photobucket.com/albums/...06141514_n.jpg

http://i1315.photobucket.com/albums/...46096773_n.jpg

http://i1315.photobucket.com/albums/...19316396_n.jpg

http://i1315.photobucket.com/albums/...86458870_n.jpg

http://i1315.photobucket.com/albums/...04417746_n.jpg

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

Perfection is not an accident. Very nice.

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

Thanks Douglas!


Friday we mounted the bed on a rotisserie to work on it easier.

http://i1315.photobucket.com/albums/...84570814_n.jpg


The inner fenderwell was beat up pretty badly and the concave area was nearly flat.

http://i1315.photobucket.com/albums/...45016304_n.jpg

http://i1315.photobucket.com/albums/...07732059_n.jpg

http://i1315.photobucket.com/albums/...68169603_n.jpg

http://i1315.photobucket.com/albums/...23162221_n.jpg

http://i1315.photobucket.com/albums/...10595341_n.jpg


After lots of beating with a sledge hammer, dollies, and wood blocks.

http://i1315.photobucket.com/albums/...37005917_n.jpg


Flatter than it was, still not all the way there.

http://i1315.photobucket.com/albums/...18057487_n.jpg

http://i1315.photobucket.com/albums/...18329054_n.jpg


Bottom half smoothed up.

http://i1315.photobucket.com/albums/...81604480_n.jpg


Flat bottom 1/2.

http://i1315.photobucket.com/albums/...25537580_n.jpg



Made a new bedside flange since the old was was so beat up.

http://i1315.photobucket.com/albums/...47625125_n.jpg

http://i1315.photobucket.com/albums/...32843967_n.jpg

http://i1315.photobucket.com/albums/...54667575_n.jpg


Reshaping the bed corner flange to fit the bedside flange using a shrinker/stretcher.

http://i1315.photobucket.com/albums/...29583826_n.jpg

http://i1315.photobucket.com/albums/...96528665_n.jpg

http://i1315.photobucket.com/albums/...40401440_n.jpg

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

Tailgate ends were seam sealed with SEM epoxy sealer.

http://i1315.photobucket.com/albums/...00206065_n.jpg


Letters were masked before spraying Slick Sand to preserve the stamping crispness.

http://i1315.photobucket.com/albums/...24705126_n.jpg



Inside corner was blasted and shot with PPG DP epoxy.

http://i1315.photobucket.com/albums/...46352573_n.jpg

http://i1315.photobucket.com/albums/...67742724_n.jpg


Corner welded back on.

http://i1315.photobucket.com/albums/...70059429_n.jpg


Floor welds ground smooth.

http://i1315.photobucket.com/albums/...17624578_n.jpg


Checking the fit of the tailgate.

http://i1315.photobucket.com/albums/...10941924_n.jpg

http://i1315.photobucket.com/albums/...20862604_n.jpg

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

Amazing work.

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

VERY nice work!

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

Thanks dudes!

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

The bottom right bed corner didn't fit well at the seam against the bedside so we made cuts and re-aligned the two panels.

http://i1315.photobucket.com/albums/...71230378_n.jpg


After cutting welding, and smoothing the welds.

http://i1315.photobucket.com/albums/...82473718_n.jpg

http://i1315.photobucket.com/albums/...46599927_n.jpg



The very bottom of the corner didn't fit either so we cut/reshaped it.

http://i1315.photobucket.com/albums/...96790453_n.jpg

http://i1315.photobucket.com/albums/...45580114_n.jpg


The rolled curve in the body line didn't match, same treatment.

http://i1315.photobucket.com/albums/...35099095_n.jpg

http://i1315.photobucket.com/albums/...38325486_n.jpg

http://i1315.photobucket.com/albums/...76186127_n.jpg

http://i1315.photobucket.com/albums/...14087544_n.jpg


Finding the dents in the left wheel tub with sandpaper and straightening them with a hammer/dolly.

http://i1315.photobucket.com/albums/...79911218_n.jpg

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

Those body lines didn't look that from the factory.

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

Yeah some of them were off quite a bit. The doors will be the same way.

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

We have the bed prepped for epoxy so we started on the doors. The top of the passenger door was pretty beat so we finally decided to cut the whole skin off to get to the damage better.


http://i1315.photobucket.com/albums/...32988115_n.jpg


Checking the damage with a straight edge.

http://i1315.photobucket.com/albums/...61053075_n.jpg

http://i1315.photobucket.com/albums/...53495190_n.jpg


Skin off, more rust than expected. This would have come through in a few more years if not addressed now. We blasted the frame and welded up the pin holes.

http://i1315.photobucket.com/albums/...03043853_n.jpg

http://i1315.photobucket.com/albums/...00664281_n.jpg

http://i1315.photobucket.com/albums/...86632094_n.jpg



The new emblem studs were slightly off from the original holes, and slightly larger. I stuck the emblems on and marked where the holes needed enlarging to make them fit properly.

http://i1315.photobucket.com/albums/...86319461_n.jpg

http://i1315.photobucket.com/albums/...73115669_n.jpg

http://i1315.photobucket.com/albums/...28692613_n.jpg


Checking the fit of the clips.

http://i1315.photobucket.com/albums/...17179788_n.jpg


Inside of door blasted and painted with Chassis Saver.

http://i1315.photobucket.com/albums/...89465767_n.jpg

http://i1315.photobucket.com/albums/...15965707_n.jpg


Door skin before straightening.

http://i1315.photobucket.com/albums/...53157147_n.jpg



Finding the high/low spots by block sanding.

http://i1315.photobucket.com/albums/...29550946_n.jpg



Door skin straightened above the body line.

http://i1315.photobucket.com/albums/...74701120_n.jpg



Marking the location of the sunk in areas on the bottom skin.

http://i1315.photobucket.com/albums/...64089963_n.jpg


Rolling on an english wheel to bring the skin up.

http://i1315.photobucket.com/albums/...80792999_n.jpg



Sound deadener inside the door frame.

http://i1315.photobucket.com/albums/...59396124_n.jpg


Ready to start on the driver's door next week.

http://i1315.photobucket.com/albums/...90989111_n.jpg

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

astronaut,

Great build, your work is excellent. Just a thought, now that the doors are apart it would be the right time to weld in some anti-intrusion bars, just like all modern cars. Heaven forbid that some clown would T-bone you, but they could save your life if that happened.

Regards from Down Under. :chevy:

aussiejohn

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

Hadn't thought of that, good idea but we already have the doors tacked back together now.

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

Here's what we did yesterday and today. We moved the cab around to the stall we usually work out of since the doors were nearly ready for fitting.


Driver side door finished, coated with Chassis Saver and two layers of sound deadening. They don't sound like tin cans anymore!

http://i1315.photobucket.com/albums/..._1096945_n.jpg



Doors installed to check fit and rework the edges where things didn't line up.

http://i1315.photobucket.com/albums/...84465761_n.jpg



Front edge against cowl box didn't fit the shape.

http://i1315.photobucket.com/albums/...11233536_n.jpg



Heat shrunk to pull the edge down, then shaped with a hammer/dolly to match the shape of the cowl panel.

http://i1315.photobucket.com/albums/...06933314_n.jpg

http://i1315.photobucket.com/albums/...59066594_n.jpg



Back edge fit was decent already.

http://i1315.photobucket.com/albums/...26042551_n.jpg


Bottom edge needed some straightening.

http://i1315.photobucket.com/albums/...94428653_n.jpg


This was one of the two areas that fit terribly.

http://i1315.photobucket.com/albums/...62399762_n.jpg


Difference between the door skin shape (red profile gauge) and the cowl edge.

http://i1315.photobucket.com/albums/...11235617_n.jpg


Relief cuts.

http://i1315.photobucket.com/albums/...74894627_n.jpg


Reshaped the edge, checking the shape.

http://i1315.photobucket.com/albums/...51685723_n.jpg

http://i1315.photobucket.com/albums/...89098438_n.jpg

http://i1315.photobucket.com/albums/...40993909_n.jpg


Cuts welded and smoothed.

http://i1315.photobucket.com/albums/...66969827_n.jpg


Fits flush, it looks a little off since the gaps aren't even yet.

http://i1315.photobucket.com/albums/...14214697_n.jpg

http://i1315.photobucket.com/albums/...79872979_n.jpg



This was the second area that fit really bad. The cab stuck out from the window frame by 3/16". Both sides were like this, tapering in towards the top.

http://i1315.photobucket.com/albums/...34881614_n.jpg

http://i1315.photobucket.com/albums/...97333909_n.jpg

http://i1315.photobucket.com/albums/...81428317_n.jpg

http://i1315.photobucket.com/albums/...81428317_n.jpg


After relief cutting the door jamb, aligning, welding, and smoothing.

http://i1315.photobucket.com/albums/...38169932_n.jpg

http://i1315.photobucket.com/albums/...08662541_n.jpg

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

We cleaned off the back of the fenders to see what the original primer color was... light gray. There was a very thin coat of Sahara Beige that would wipe off with wax and grease remover, we'll replicate this when we paint the fenders.

http://i1315.photobucket.com/albums/...14743704_n.jpg

http://i1315.photobucket.com/albums/...99867641_n.jpg


Mocked up the fenders to check their fit. The passenger side has a bulge at the bottom. We'll try to find another one since there are 5 long creases hiding under the paint; it's full of bondo.

http://i1315.photobucket.com/albums/...94219662_n.jpg

http://i1315.photobucket.com/albums/...18751529_n.jpg



The driver's fender was much better, it won't need much work to fit the door perfectly.

http://i1315.photobucket.com/albums/...91606666_n.jpg



Didn't post this earlier, but we shot weld-thru coating on the door skin flanges.

http://i1315.photobucket.com/albums/...03328541_n.jpg

http://i1315.photobucket.com/albums/...49028842_n.jpg


Rust in the right rear cab corner.

http://i1315.photobucket.com/albums/...41973964_n.jpg

http://i1315.photobucket.com/albums/...58433292_n.jpg


Blasted, pinholes welded up, inner cavity painted with Chassis Saver. Used a long dauber to reach farther up into the cavity to get more paint in there.

http://i1315.photobucket.com/albums/...06888263_n.jpg

http://i1315.photobucket.com/albums/...14462593_n.jpg

http://i1315.photobucket.com/albums/...99849900_n.jpg



Marking the door edge for cutting. I use 1/8" steel welding rods on the edges of the doors to reset the gaps.

http://i1315.photobucket.com/albums/...63312880_n.jpg

http://i1315.photobucket.com/albums/...37277350_n.jpg


Door edge cut back, inner/outer skins tacked together.

http://i1315.photobucket.com/albums/...24589691_n.jpg


Nylon feeler gauge for checking the size of the gap.

http://i1315.photobucket.com/albums/...62865387_n.jpg


Welding rod bend to fit the door edge, tacked in place.

http://i1315.photobucket.com/albums/...77713311_n.jpg


Fully welded.

http://i1315.photobucket.com/albums/...58771491_n.jpg


Welds smoothed. The gap is too small, but there is a full 1/8" of material to grind back without the edge splitting.

http://i1315.photobucket.com/albums/...79394747_n.jpg