My new Project

[bucks77ford]

A little more work done. I made the small patch out of 20 gauge sheet metal, worked pretty good. There was 2 small pin holes in the same rear spot on the drivers side and I initially thought about just filling those with Fiberstrand Body Filler because the surrounding metal was solid, but decided against it and cut out another small section like I did on the passenger side there and welding that in. Pics later.

I also spent a good deal of time getting the bed ready for removal. Dang 30 plus years of rust doesn't make things easy that's for sure. There was only 4 bed bolts holding it on and the rears came off easy, but I ended up having to weld a nut to the top of the front ones so I could get those out. If you noticed in the beginning there was some mud flaps on the rear and the bracket for those was welded to the frame, so I had to cut those off. The screws holding the filler necks to the bed were a pain. It's amazing what you find though taking things apart. Stuck in the rear tail lights was some plastic of some sort like small parts of bags or something. How that crap gets there is beyond me. No wonder these things rust out so much. Crap gets stuck everywhere and holds all the grime and moisture. Took some time, but the bed is ready to come off when it's time. My plan is to get the bed on some sort of trailer or dollies so I can move it around and then I'll be able to get it to a point of epoxy primer. Once I get that far, I'll start working on the cab. I don't think my wife is going to be happy when it starts snowing and I have her van parked outside all winter.

 

[Workin' Rig]

Awesome truck! Hows the interior?

 

[fatherdoug]

A little more work done. I made the small patch out of 20 gauge sheet metal, worked pretty good. There was 2 small pin holes in the same rear spot on the drivers side and I initially thought about just filling those with Fiberstrand Body Filler because the surrounding metal was solid, but decided against it and cut out another small section like I did on the passenger side there and welding that in. Pics later.

I also spent a good deal of time getting the bed ready for removal. Dang 30 plus years of rust doesn't make things easy that's for sure. There was only 4 bed bolts holding it on and the rears came off easy, but I ended up having to weld a nut to the top of the front ones so I could get those out. If you noticed in the beginning there was some mud flaps on the rear and the bracket for those was welded to the frame, so I had to cut those off. The screws holding the filler necks to the bed were a pain. It's amazing what you find though taking things apart. Stuck in the rear tail lights was some plastic of some sort like small parts of bags or something. How that crap gets there is beyond me. No wonder these things rust out so much. Crap gets stuck everywhere and holds all the grime and moisture. Took some time, but the bed is ready to come off when it's time. My plan is to get the bed on some sort of trailer or dollies so I can move it around and then I'll be able to get it to a point of epoxy primer. Once I get that far, I'll start working on the cab. I don't think my wife is going to be happy when it starts snowing and I have her van parked outside all winter.

Buck, you might take a look at Duncan's build. He had a nice set of dollies built out of 2 X 4's with wheels so he could move the bed around. Don't know if you saw that or not.

I just wish I could do work like that. Keep us posted.

 

[bucks77ford]

Awesome truck! Hows the interior?

Thanks. The interior isn't too bad. Aside from needing carpet, the rest is pretty good. I'll get some pics up at some point. Needs a good cleaning.

Buck, you might take a look at Duncan's build. He had a nice set of dollies built out of 2 X 4's with wheels so he could move the bed around. Don't know if you saw that or not.

I just wish I could do work like that. Keep us posted.

I'll try to find those dollies Duncan made. I had a buddy do all my bodywork on my blue truck so this is the first time I've even tried to do my own bodywork. I figured I'd just jump in go. It's not going to perfect, but I'm not expecting perfection.

 

[DNFXDLI]

Cool post Buck...looking good. The dollies I designed and had my carpenter buddy build were real cheap....just some casters and 2x4's with a sheet of 3/8 ply or OSB to stiffen.
I took some measurements of the box/cab and made frames..well, had my buddy cut them and assemble them in pieces as I was busy and he owed me several favors...but, easy enough to do yourself.

 

[bucks77ford]

Haven't made much progress on the body work, but did make some progress on getting the bed off. I ended up making a wooden dolly/cart for the bed. I probably went a little overboard on the 2x4s, but it worked. I ended up just buying a couple moving dollies from Harbor Freight for $12 a piece and took off the casters and used 6 of em. Sure as heck cheaper than buying them separately from somewhere else. I was a little skeptical on how the casters would hold up, but so far so good.

I made a reinforced beam in the attic of my garage (nothing special) and a chain wrapped around the beam to hold my 1 ton chain hoist. Then just used some heavier straps in the stake pockets and hoist away. Worked pretty slick and I was able to accomplish a "one man truck bed removal". Some reason my camera went blurry in some of the pics below.

I'm also kinda wondering what I should do with the passenger cab corner. I cut out the rust that was obvious, but the rest of the corner looks and feels solid. Do I just go ahead and cut out the rest and replace the entire corner or just weld in the sheet metal where I cut out. I hate cutting out original sheet metal, but I'd also hate to have rust somewhere else in a year. I gotta imagine there is a bunch of crap in there with the lower trim holes. The drivers side I have to replace the entire corner.

 

[m78]

I can suggest leaving weep holes in those cab corners as you do your repairs.
The condensation from the upper parts of the cab run down there and pool .That causes the low points of the corners to rust.

 

[bucks77ford]

^^^^^^ I agree leaving weep holes. I will remember to do that.

 

[DNFXDLI]

Cool Buck!

 

[Workin' Rig]

As far as going over board on 2x4's, im a firm believer in overbuilding things not underbuilding them

You should see my ramps i use for driving vehicles onto trailers....

I have a 12ft 2x12 screwed on (with like 100 deck screws) into a treated 8 ft 4x6 square wood beam. I can load a semi with them bad boys. But they weigh 70lbs a piece.

 

[bucks77ford]

As far as going over board on 2x4's, im a firm believer in overbuilding things not underbuilding them

You should see my ramps i use for driving vehicles onto trailers....

I have a 12ft 2x12 screwed on (with like 100 deck screws) into a treated 8 ft 4x6 square wood beam. I can load a semi with them bad boys. But they weigh 70lbs a piece.

I agree with overbuilding rather than trying to save a penny and underbuild. I was actually going to double up the 2x4s on top and bottom of my bed cart, but decided against it figuring that would be way too much overkill. The bed isn't that heavy with weight distribution. Now I didn't make my chain hoist able to lift an engine or anything like that, but well enough for a bed and possibly a stripped cab.

Got my cab corners today so I'm looking forward to digging in on those.

 

[bucks77ford]

Working night shifts makes it hard for me to sleep at night, so I was awake at 3:30am so I figured I'd get up and go out to the garage to work a bit before the kidos wake up. Made a little more progress. I sanded down the wheel arches. Still a little work to do, but getting there. I also started to drill out the spot welds on the drivers side cab corner. I ordered some replacement cab corners from Mill Supply because I liked how the wheel arch panels fit, but different story on the cab corners. I don't like how they line up over the original, but it may be different when the panels are cut and in place. I don't know. I did find some corners on ebay from a guy that supposed to be 18G steel instead of the 20G I have. So, I ordered a Drivers side and I'll wait and see if it fits any different and compare.

 

[BuzzGun79]

Your doing great Buck...wheel arches are coming out well,Dont sweat on the cab corners to much..once the old are cut out.a little time and patience for fitment they will fit in place.I now what your trying to do by putting the panel over the existing panel to see...prolblem with this is the old panel is underneath throwing off the fit.When it comes to panels a fraction of an inch makes a big differance,you will see.it will all work out in time man.

 

[bucks77ford]

Your doing great Buck...wheel arches are coming out well,Dont sweat on the cab corners to much..once the old are cut out.a little time and patience for fitment they will fit in place.I now what your trying to do by putting the panel over the existing panel to see...prolblem with this is the old panel is underneath throwing off the fit.When it comes to panels a fraction of an inch makes a big differance,you will see.it will all work out in time man.

Thanks man. I'm sure you are right on the fitment. The door jamb side of the corner just seems way off, like the corner is too long. I'm sure I can get it into place OK with some hammering.

May plan on the passenger side is too drill out the spot welds and see if I can get all the crap out that is trapped in there and hopefully just fix the rear and rest is OK, but I'm not sure how thin the metal is underneath.

 

[bucks77ford]

Kinda wish I had a bigger garage. I've got the damn thing crowded. My wife hates it because her van has to sit outside.

 

[m78]

Your garage looks fairly neat compared to some I've seen.

 

[Beach66Bum]

If I had a garage, my truck wouldn't be Orange.....
I agree, nice garage to work in

 

[460Trucker]

If I had a garage, my truck wouldn't be Orange.....

WHAT????

 

[DNFXDLI]

You are making good progress!

 

[BuzzGun79]

Buck..Just tell the wife "priorities take presidence over the van...and yes dear ill clean the snow off your windows"....hehe