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

We bodyworked the doors, firewall, and kick panels and got them shot with PPG K36 high build. Also seam sealed the door jambs, inside the cab, the firewall, and the drip rails.


http://i1315.photobucket.com/albums/...22286602_n.jpg


Masked any stamped numbers to preserve the details.

http://i1315.photobucket.com/albums/...69664444_n.jpg


Kick panels primed and seam sealed.

http://i1315.photobucket.com/albums/...59604835_n.jpg

http://i1315.photobucket.com/albums/...81148098_n.jpg


Seam sealed with Fusor 122 self leveling seam sealer. Flows out almost glass smooth.

http://i1315.photobucket.com/albums/...92952650_n.jpg

http://i1315.photobucket.com/albums/...46954621_n.jpg


Roof seam.

http://i1315.photobucket.com/albums/...89849859_n.jpg

http://i1315.photobucket.com/albums/...08862963_n.jpg


Inside of doors didn't need much, only had a few ripples across the bottoms.

http://i1315.photobucket.com/albums/...32946066_n.jpg



Shot with K36.

http://i1315.photobucket.com/albums/...70895369_n.jpg

http://i1315.photobucket.com/albums/...15959626_n.jpg

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

Man, you guys do nice work! Good blocking tips, too. Do you dry block to 320?

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

Thanks! We go up to 180 when dry blocking.

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

We blasted the vent frames and shot them with epoxy, then high build.

http://i1315.photobucket.com/albums/...60777375_n.jpg


Door jambs masked, ready to shoot with high build.

http://i1315.photobucket.com/albums/...91042864_n.jpg

http://i1315.photobucket.com/albums/...13253704_n.jpg

http://i1315.photobucket.com/albums/...51555906_n.jpg


Sprayed with K36.

http://i1315.photobucket.com/albums/...13150306_n.jpg


Starting to work the pan graft areas underneath. This is where a rotisserie is really handy!

http://i1315.photobucket.com/albums/...83770712_n.jpg

http://i1315.photobucket.com/albums/...34877470_n.jpg


Roof skimmed and blocked, ready for Slick Sand.

http://i1315.photobucket.com/albums/...57762422_n.jpg


If you've been wondering about how much filler stays on the panel, this is what was blocked off just the center section of the roof, not the sides. This was also with a fan blowing, so this isn't all that was blocked off. Doesn't take much to make a mess of the shop when dry blocking!

http://i1315.photobucket.com/albums/...98612489_n.jpg

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

Shot the roof with Slick Sand last night, and the floor bottom with K36.


http://i1315.photobucket.com/albums/...34499163_n.jpg

http://i1315.photobucket.com/albums/...19388140_n.jpg

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

Starting the radio patch panel.

http://i1315.photobucket.com/albums/...16719087_n.jpg


Shaped to fit the contour of the dash.

http://i1315.photobucket.com/albums/...62608786_n.jpg


Cut line scribed.

http://i1315.photobucket.com/albums/...55622802_n.jpg


Fitted and tacked in place.

http://i1315.photobucket.com/albums/...91784576_n.jpg


Fully welded and smoothed.

http://i1315.photobucket.com/albums/...56098292_n.jpg

http://i1315.photobucket.com/albums/...32120189_n.jpg


Leveled the cab, then leveled the face plate mount to mark the holes that need to be drilled.

http://i1315.photobucket.com/albums/...04955015_n.jpg


Radio mounted.

http://i1315.photobucket.com/albums/...92533031_n.jpg


Made a support brace from 1/8" plate.

http://i1315.photobucket.com/albums/...53974427_n.jpg


Picked up the fenders, hood, splash, and grill panel from the blaster.

http://i1315.photobucket.com/albums/...44929823_n.jpg


This one needs a bit of work!

http://i1315.photobucket.com/albums/...14516858_n.jpg

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

A lot of detail work going on there, looks awesome. Truck will be brand new and ready for another 50 years!

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

Thanks Robert, means a lot coming from you! Been watching your '55 topic, VERY nice work you do!!

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

After lunch I bolted up the glove box door to check its fit. I remembered it being pretty bad before we dissassembled the truck. The top right corner was overlapping it's jamb if I adjusted it up enough so the bottom edge was flush.


http://i1315.photobucket.com/albums/...65127242_n.jpg

http://i1315.photobucket.com/albums/...31579116_n.jpg


Cut lines laid out.

http://i1315.photobucket.com/albums/...36862937_n.jpg


After cutting it still wouldn't shut all the way. The hinge brace was hitting the jamb, so I had to reshape those areas for better clearance.

http://i1315.photobucket.com/albums/...90456934_n.jpg


Fitting flush now.

http://i1315.photobucket.com/albums/...64471407_n.jpg


1/8" welding rod will fill in the gap.

http://i1315.photobucket.com/albums/...70892018_n.jpg


Right edge still needs trimming.

http://i1315.photobucket.com/albums/...49099951_n.jpg


The ash tray fit worst than the glove box door, with no way to adjust it from the factory.

http://i1315.photobucket.com/albums/...12073637_n.jpg


The hinge rod is crooked...

http://i1315.photobucket.com/albums/...35261791_n.jpg


The inner hinge bracket fit the dash so tightly that it couldn't be adjusted outward.

http://i1315.photobucket.com/albums/...69451329_n.jpg


After trimming the edges of the bracket to allow ample adjustment.

http://i1315.photobucket.com/albums/...06187435_n.jpg


Starting to reshape the edges to fit flush.

http://i1315.photobucket.com/albums/...39714764_n.jpg


Fits level now after reworking the hinge rod. Gaps still need to be tightened up with welding rods.

http://i1315.photobucket.com/albums/...33174390_n.jpg


Way closer than it was, ran out of time to finish them today.

http://i1315.photobucket.com/albums/...08319465_n.jpg

http://i1315.photobucket.com/albums/...67391304_n.jpg


Before dissassembly.

http://i1315.photobucket.com/albums/...ps8067fe9d.jpg

http://i1315.photobucket.com/albums/...ps46f41de6.jpg

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

Been slacking on posting pics, here's where we're at.

Doors installed and aligned.

http://i1315.photobucket.com/albums/...84272657_n.jpg


Skim coated across the panel gaps. After blocking the panels will be dead flush.

http://i1315.photobucket.com/albums/...31499146_n.jpg


Frame wrapped with moving blankets, macking paper, and stretch wrap to protect from overspray.

http://i1315.photobucket.com/albums/...48614880_n.jpg

http://i1315.photobucket.com/albums/...64317284_n.jpg


Cab back on frame so we can install and align/fit the front clip.

http://i1315.photobucket.com/albums/...37120233_n.jpg

http://i1315.photobucket.com/albums/...60085203_n.jpg

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

Got most of the kinks worked out of the front clip.


The hinge bottoms were hitting the pinchweld and wouldn't let us adjust the hood down far enough.

http://i1315.photobucket.com/albums/...45404089_n.jpg


After:

http://i1315.photobucket.com/albums/...87679614_n.jpg


The radiator support was too high, so the fender didn't fit right and the hood ran uphill.

http://i1315.photobucket.com/albums/...26755083_n.jpg


The fender also didn't fit the shape of the door edge, so we had to flatten it.

http://i1315.photobucket.com/albums/...97337762_n.jpg


After standing on it with the inner brace supported top and bottom.

http://i1315.photobucket.com/albums/...37616721_n.jpg


Hood adjusted/bent to fit flush with the cowl.

http://i1315.photobucket.com/albums/...47343966_n.jpg


The fender to filler panel fit was horrible, paint would have chipped as soon as the bolts were snugged up.

http://i1315.photobucket.com/albums/...05458064_n.jpg

http://i1315.photobucket.com/albums/...70899034_n.jpg


After straightening the gap out.

http://i1315.photobucket.com/albums/...71243314_n.jpg

http://i1315.photobucket.com/albums/...76110322_n.jpg


Driver side fender gap. Needs to be opened up a hair at the top.

http://i1315.photobucket.com/albums/...41045649_n.jpg


Hood damage.

http://i1315.photobucket.com/albums/...30725373_n.jpg


Bumper slots in the filler panel didn't line up, even though the bumper fit perfectly with the holes in the frame horns.

http://i1315.photobucket.com/albums/...30084857_n.jpg


Fender and filler panel corners stuck out past the hood edge.

http://i1315.photobucket.com/albums/...98210930_n.jpg


After cutting and reshaping.

http://i1315.photobucket.com/albums/...68743813_n.jpg

http://i1315.photobucket.com/albums/...65407248_n.jpg


Frame/engine protected from welding splatter with a fiberglass blanket.

http://i1315.photobucket.com/albums/...16554464_n.jpg


Found some pinholes in the hood edge so we cut it out.

http://i1315.photobucket.com/albums/...68129555_n.jpg

http://i1315.photobucket.com/albums/...01964740_n.jpg


New piece welded in.

http://i1315.photobucket.com/albums/...86262634_n.jpg

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

Very interesting as always, amazing to see your extreme attention to detail.

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

Ford... Quality is Job 1... :lol:

I recently watched this video on mustang assembly, it's unbelievable to watch how the fender and hood are literally just slapped on and bolted down @ 2:18 and 2:50:

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

Thanks plainred!!



That's pretty bad!! :eek:

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

The front fender edges had some bumps where they meet up with the bumper filler panel.

http://i1315.photobucket.com/albums/...96055661_n.jpg

http://i1315.photobucket.com/albums/...87673471_n.jpg



Cut, flattened, welded, and smoothed.

http://i1315.photobucket.com/albums/...69597839_n.jpg

http://i1315.photobucket.com/albums/...44958225_n.jpg


The splash panel still didn't fit up well.

http://i1315.photobucket.com/albums/...33538824_n.jpg

http://i1315.photobucket.com/albums/..._2557676_n.jpg


Started straightening the fender and hood.

http://i1315.photobucket.com/albums/...49764991_n.jpg

http://i1315.photobucket.com/albums/...02271801_n.jpg


Primed the back of the cab with Slick Sand.

http://i1315.photobucket.com/albums/...34400685_n.jpg


Steering box is back from being rebuild by Red Head Gear.

http://i1315.photobucket.com/albums/...91204668_n.jpg


At some point the battery had exploded and etched/rusted the hood skin. The soda blasting didn't take it off, and sand blasting would warp the skin. We coated the area with Naval Jelly, covered it in plastic, and let it soak overnight. That got most of the rust out. We scrubbed the rest with steel bristle brushes and let it soak more.

http://i1315.photobucket.com/albums/...48709476_n.jpg

http://i1315.photobucket.com/albums/...20101947_n.jpg


Most of the rust gone.

http://i1315.photobucket.com/albums/...79185913_n.jpg

http://i1315.photobucket.com/albums/...58285316_n.jpg


After more soaking, neutralizing the acid with baking soda, then washing with PPG DX579 and DX520. The rust is gone and the acid is neutralized so there shouldn't be problems later on.

http://i1315.photobucket.com/albums/...09992432_n.jpg


Top of hood washed with DX579/520.

http://i1315.photobucket.com/albums/...78840094_n.jpg


Checking the fender fit before skimming across the gap.

http://i1315.photobucket.com/albums/...60362988_n.jpg

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

Your attention to small details is amazing. I would love to see this truck when you finish it.

"I recently watched this video on mustang assembly, it's unbelievable to watch how the fender and hood are literally just slapped on and bolted down"

That's how cars were built in the sixties, and the funny thing is, we didn't notice the mis-matched panels and wide gaps back then.

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

Come over and check it out!!

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

With the metalwork smoothed out and the panels aligned, we skimmed all the panels together then blocked them together. This way they're all exactly flush.

http://i1315.photobucket.com/albums/...11252476_n.jpg


Hood shot with PPG DPLF epoxy.

http://i1315.photobucket.com/albums/...17269344_n.jpg


After all the rough bodywork was done we shot it with Slick Sand.

http://i1315.photobucket.com/albums/...61295589_n.jpg

http://i1315.photobucket.com/albums/...21677271_n.jpg

http://i1315.photobucket.com/albums/...31457387_n.jpg



Even gaps.

http://i1315.photobucket.com/albums/...61185938_n.jpg



Hood corner fit, starts to poke out around the curve so to match the front panel to hood edge fit.

http://i1315.photobucket.com/albums/...52298570_n.jpg

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

I've seen this before mudding over gaps, but what I've yet to see or hear or read. How do you sand it w/o it chipping apart when removing the filled void?
Hope this question makes sence.

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

I have a 1/8" bit I use with a straight shaft grinder to open the seam back up. We do that before sanding, no problems with chipping in the edges that way.

http://i1315.photobucket.com/albums/...ps8414f97d.jpg

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

Yikes! that looks menacing! :lol:
Its clear your a busy man but here is a thought. Video of the next time you do that "skim over gap" and add it to your sanding thread?

Maybe others will chime in?

Back to your Ford! Which is looking awesome!

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

This is one of those threads that you can go back over it again and again and always pick up something new.

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

I just found this one, VERY nice work, as always! Im along for the ride.

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

Great work. Love the metal detail you guys put into it. That's the small things that make that unnoticable big difference in the end.

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

Thanks! We're way past that stage on the F100, so it'll have to be the next project before I can get shoot a vid of that.



Thanks James!


Glad you like it!



Thanks!