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

Dang you have entertained me and maybe changed my mind about getting a beater old Ford someday. Not sure I could handle all that work at my age. LOL
Thanks for the great write up and of course the quality work! Love this build!

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

Thanks NONHOG!

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

Shot the bed with PPG DPLF epoxy thursday night.

http://i1315.photobucket.com/albums/...93249924_n.jpg



Masked and applied epoxy seam sealer Friday morning. Don't use blue tape for seam sealer, it's tough to get it back off without it tearing to shreds!

http://i1315.photobucket.com/albums/...20597132_n.jpg

http://i1315.photobucket.com/albums/...66641085_n.jpg

http://i1315.photobucket.com/albums/...19832696_n.jpg

http://i1315.photobucket.com/albums/...16562575_n.jpg



Turned the bed up so we could hammer/dolly the dents out of the bed floor.

http://i1315.photobucket.com/albums/...04790204_n.jpg


Skim coated a few spots.

http://i1315.photobucket.com/albums/...10256603_n.jpg

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

Right side bodywork roughed in and shot with Slick Sand.

http://i1315.photobucket.com/albums/...32231043_n.jpg

http://i1315.photobucket.com/albums/...43280714_n.jpg

http://i1315.photobucket.com/albums/...26678189_n.jpg

http://i1315.photobucket.com/albums/...50158274_n.jpg


Passenger side metal shaping finished.

http://i1315.photobucket.com/albums/...18104246_n.jpg

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

Mud time, my favorite part of the restoration process!! :waah:


Skimmed across the seam to get both side dead even.

http://i1315.photobucket.com/albums/...9_304619_n.jpg

http://i1315.photobucket.com/albums/...52247487_n.jpg


Then skimmed and blocked the whole side.

http://i1315.photobucket.com/albums/...34000133_n.jpg

http://i1315.photobucket.com/albums/...16393756_n.jpg


Started blocking the left side.

http://i1315.photobucket.com/albums/...34363017_n.jpg



Rodney started working the inside of the bed.

http://i1315.photobucket.com/albums/...96877201_n.jpg

http://i1315.photobucket.com/albums/...31896652_n.jpg

http://i1315.photobucket.com/albums/...71391177_n.jpg

http://i1315.photobucket.com/albums/...17661914_n.jpg

http://i1315.photobucket.com/albums/...46366688_n.jpg

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

If I ever win the lottery, I'm sending you every car I own.

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

Sounds good to me! :metal:

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

Some details of sanding the primer. I sand the flat areas first, then hit the edges with guidecoat so I can see how much primer I'm taking off the edge, and also how evenly I'm blocking the edge. This keeps the diameter and shape of the edge even front to back.

http://i1315.photobucket.com/albums/...50247009_n.jpg


Roll above the edge and the flat area below sanded first.

http://i1315.photobucket.com/albums/...56799148_n.jpg


Shot with guide coat.

http://i1315.photobucket.com/albums/...61141281_n.jpg


Edge blocked. You can see how far the new edge shape comes over into the upper roll and lower flat panel.

http://i1315.photobucket.com/albums/...39183139_n.jpg


Sanding/shaping the bed side seam using a 1/8" welding rod wrapped in sandpaper.

http://i1315.photobucket.com/albums/...28614826_n.jpg

http://i1315.photobucket.com/albums/...70503792_n.jpg


Ready to shape the lower edge of the upper bed panel.

http://i1315.photobucket.com/albums/...09264216_n.jpg


After sanding.

http://i1315.photobucket.com/albums/...92822658_n.jpg


Left side blocked, a couple spots touched up, seams/edges detail sanded. Ready for blocking with 180 and shot with more Slick Sand.

http://i1315.photobucket.com/albums/...18345719_n.jpg

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

Masked out the right side and shot a few coats of Slick Sand.

http://i1315.photobucket.com/albums/...16946000_n.jpg

http://i1315.photobucket.com/albums/...00013603_n.jpg

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

Still checking in and following along, very nice work as always.

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

Thanks! :metal:

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

Sprayed inside the bed, the header panel, and the left bedside sprayed with Slick Sand today.


Shaped a piece of foam to fit the bed floor ridges and glued it to a jitterbug sander to prep the bed floor before primer.

http://i1315.photobucket.com/albums/...68347405_n.jpg


Some shots of the primer. This part of the resto gets kinda repetitive...

http://i1315.photobucket.com/albums/...20433515_n.jpg

http://i1315.photobucket.com/albums/...62495565_n.jpg

http://i1315.photobucket.com/albums/...46319449_n.jpg

http://i1315.photobucket.com/albums/...47342485_n.jpg

http://i1315.photobucket.com/albums/...88184567_n.jpg

http://i1315.photobucket.com/albums/...46773490_n.jpg

http://i1315.photobucket.com/albums/...44706030_n.jpg



Some shots while it was still wet.

http://i1315.photobucket.com/albums/...13967895_n.jpg

http://i1315.photobucket.com/albums/...87271818_n.jpg

http://i1315.photobucket.com/albums/...76199901_n.jpg

http://i1315.photobucket.com/albums/...48464302_n.jpg

http://i1315.photobucket.com/albums/...90061862_n.jpg

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

spray sand spray sand spray sand are we there yet I gotta go :lol:

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

That's about it, bathroom breaks and a stop now and then to stretch your legs. The bed floor was a back and knee killer, even with the rotisserie. Anyone got any low mileage arms and fingers I can borrow? :lol:
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Re: 1966 F100 Short/Fleet Full Stock Resto Build Thread
 

More block sanding... Seems like this part never ends! We did this Tuesday and Wednesday, Rodney took the day off and I cleaned up and extra stall we weren't using. My arms needed a rest from blocking for two days straight. :lol:

I cut down and reshaped a Durablock to fit the bed floor grooves.

http://i1315.photobucket.com/albums/...63153948_n.jpg


Then glued it to an inline sander. This saved a ton of time! I usually hate these things for any other kind of sanding but it worked well for this.

http://i1315.photobucket.com/albums/...35777424_n.jpg


After blocking the top and bottom grooves, the edges needed sanding. Bottom masked off to keep the block from cutting stray grooves into the primer.

http://i1315.photobucket.com/albums/...54312158_n.jpg

http://i1315.photobucket.com/albums/...24359610_n.jpg


After sanding.

http://i1315.photobucket.com/albums/...53218940_n.jpg


Fixing the high/low spots with a skim of filler.

http://i1315.photobucket.com/albums/...34714593_n.jpg


Blocking the driver side... again.

http://i1315.photobucket.com/albums/...98558962_n.jpg


Using PVC to shape the concave area.

http://i1315.photobucket.com/albums/...49285599_n.jpg


Checking the reflection after blocking with 80 grit by wiping wax and grease remover over the surface. You can see how well the reflection carries over from the bed side to the bed corner.

http://i1315.photobucket.com/albums/...26471582_n.jpg


The spot that was cut out and welded back in didn't need any filler, any distortion blocked out with just high build.

http://i1315.photobucket.com/albums/...31861970_n.jpg

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

That's a lot of work on the inside of the bed hope it doesn't get used as a truck when your done.

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

We will be on an episode of America's Most Wanted if he attempts to haul anything in the bed... :lol:

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

Well, the inside of the bed is all been blocked out, and any high/low spots touched up. Just shot three coats of PPG K36 so we can wetsand and paint it. The outside of the bed bed is in Slick Sand, ready for what should be the last round of blocking.

http://i1315.photobucket.com/albums/...38277394_n.jpg

http://i1315.photobucket.com/albums/...21489781_n.jpg

http://i1315.photobucket.com/albums/...93794594_n.jpg

http://i1315.photobucket.com/albums/...50969679_n.jpg

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

I'd be so terrified that someone would toss something in the bed that I would make a clear Lexan tonneau cover!

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

:haha:

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

Did some work on the door gaps. Welded up the edges with 1/8" steel welding rods to close the gap, then used a feeler gauge to get them all even.

http://i1315.photobucket.com/albums/...17000433_n.jpg

http://i1315.photobucket.com/albums/...56474903_n.jpg

http://i1315.photobucket.com/albums/...89096542_n.jpg

http://i1315.photobucket.com/albums/...11581626_n.jpg

http://i1315.photobucket.com/albums/...72473263_n.jpg



Also made a new cab corner piece. It has a few bumps from hammering it out but it'll hafta do. These are unavailable.

http://i1315.photobucket.com/albums/...86446060_n.jpg

http://i1315.photobucket.com/albums/...11058747_n.jpg

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

Inside of cab corner coated with chassis saver and welded on. I left the bottom edge uneven to match the factory sloppiness.


http://i1315.photobucket.com/albums/...92031338_n.jpg

http://i1315.photobucket.com/albums/...95737498_n.jpg


Right door gaps mostly finished. Need to go across the bottom still, and can't do the front edge until the front clip is on.
http://i1315.photobucket.com/albums/...62754760_n.jpg

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

Had to make the cowl drains since they aren't reproduced. Started with a paper template, the wrinkles show what areas need to be shrunk.


http://i1315.photobucket.com/albums/...16304365_n.jpg

http://i1315.photobucket.com/albums/...11950480_n.jpg

http://i1315.photobucket.com/albums/...57593666_n.jpg

http://i1315.photobucket.com/albums/...60790820_n.jpg

http://i1315.photobucket.com/albums/...82791872_n.jpg

http://i1315.photobucket.com/albums/...71400458_n.jpg

http://i1315.photobucket.com/albums/...20366566_n.jpg

http://i1315.photobucket.com/albums/...89596738_n.jpg


Prepped the passenger side with Chassis Saver. Have to get the kick panel in before I can finish the drain for this side.

http://i1315.photobucket.com/albums/...00940913_n.jpg


Fitted and tacked the driver side floor in place.

http://i1315.photobucket.com/albums/...79428313_n.jpg


Then fully welded.

http://i1315.photobucket.com/albums/...99536174_n.jpg

http://i1315.photobucket.com/albums/...93151553_n.jpg



Kick panel tacked in place.

http://i1315.photobucket.com/albums/...38978027_n.jpg

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

Haven't posted lately so here's the updates. We're finished with metalwork on the cab and doors and have them in epoxy.


Passenger floor fitted and welded in.

http://i1315.photobucket.com/albums/...56212972_n.jpg


We drilled a couple 1/8" holes in each end of the hinges while the doors were bolted up and aligned. Next time we install the doors we can use 1/8" welding rods to easily align the holes, and the doors will be 95% adjusted on the first try.

http://i1315.photobucket.com/albums/...17126851_n.jpg


The windshield and back glass pinchwelds were extremely rough and wavy.

http://i1315.photobucket.com/albums/...86245830_n.jpg

http://i1315.photobucket.com/albums/...86931192_n.jpg


After straightening and smoothing. The glass will be easier to install and the rubber will lay down evenly across the pinchweld.

http://i1315.photobucket.com/albums/...11183525_n.jpg

http://i1315.photobucket.com/albums/...53477621_n.jpg


Door skins were seam sealed from the inside out, and the drains were reopened with a dremel after the sealer dried.

http://i1315.photobucket.com/albums/...89624273_n.jpg



Doors prepped for epoxy using PPG DX579 and DX520.

http://i1315.photobucket.com/albums/...45143184_n.jpg

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

We mounted the cab on a rotisserie so we could grind the welds on the bottom side.

http://i1315.photobucket.com/albums/...79079352_n.jpg


After smoothing the welds.

http://i1315.photobucket.com/albums/...18280248_n.jpg


Shot with PPG DPLF epoxy.

http://i1315.photobucket.com/albums/...25824853_n.jpg

http://i1315.photobucket.com/albums/...81004804_n.jpg

http://i1315.photobucket.com/albums/...78236858_n.jpg

http://i1315.photobucket.com/albums/...38221464_n.jpg

http://i1315.photobucket.com/albums/...93122946_n.jpg

http://i1315.photobucket.com/albums/...89795474_n.jpg

http://i1315.photobucket.com/albums/...83050349_n.jpg

http://i1315.photobucket.com/albums/...92261091_n.jpg



Won't take much bodywork to make the floor pan grafts disappear.

http://i1315.photobucket.com/albums/...56181903_n.jpg


Doors shot with epoxy.

http://i1315.photobucket.com/albums/...85258526_n.jpg