That truck is going to be so cool! I actually passed a 6 door on the highway a few weeks ago and thought of this project.

A couple questions you may have answered that I might have missed:
Where did the cab come from? I've seen a few custom trucks but I'm guessing Ford never created such a beast.

Where did you get the dimensions on how much to add to the frame? Just a matter of measuring a standard 4 door then the 6 door and adding the difference?

Finally, any plans for a color?

 

GN1220:
You are correct, Ford never offered these. Any that are out there are custom built, using 2 crew-cab cabs. I got mine by trading some guns for it. The original owner was going to build this on an F650 frame, hence the fender supports being cut short. F650s have a one piece fiberglass front do they don't need the fender supports.

When we cut and spliced the frame, the cab was still 50 miles away at my friend's race shop, so I simply took measurements off of my daily driver 02 crew cab, then added 35 1/2", the overall width of a back door including the gap.

As far as color, I'm thinking black. Everything black. No chrome anywhere, just black black black! Not flat black, but a beautiful glossy black.

 

Very nice updates. Will definitely continue watching this bulid thread.

 

Thank you for choosing glosss! Flat black is played out.

 

I got a couple of hours to work on the project today so I drilled a bunch of spot welds, pressure washed the fender/radiator support assembly then mocked it all up to see what needs to be modified to use the 06 sheetmetal and drivetrain on the 09 frame. The frame rails are too narrow for the radiator to for between, so I'll have to cut and box a small section:

 

It's going to be epic when it's completed, epic!

 

I got the F550's cab stripped, made it a convertible, pulled all the pieces off, then unbolteded the engine/tranny. When I began lifting it, the hoist started peeing oil everywhere. It blew a seal. Looks like I won't be pulling the engine today!

 

I brought another, junkier engine hoist from home and we got the engine/tranny out and into the garage. Tomorrow I'm going to pull the top off to figure out the low compression in #8.

 

I got the engine stripped down for pressure washing, then I pulled the driver's side head. The cylinders look beautiful, no ring ridge. It looks like the compression loss in cylinder #8 is coming from one of the exhaust valves. I'll know more on Saturday when I pull the valve out.

 

So in light of discovering that I need to do a full rebuild on the engine, I've changed the order of my build plans. Instead of stabbing the drivetrain into the truck then painting, I'm going to bring the engine/back to my house thouse to rebuild in my own garage. In the meantime, I'll get the bodywork all done and the truck painted. Then I can finish the wiring and reassemble the interior. Once the engine us done and the paint, interior, glass, lights and bumpers are installed, I'll lift the cab and install the drivetrain

 

PS: last night I took a couple of hours to install a gas conversion I my Lincoln Weldpak MIG welder. Now it welds beautifully and I'll be able to finish installing the sheetmetal on the front of the truck (and go over some of the uglier welds on the bottom of the cab!)



This is the solenoid valve I used from Grainger. It cost me $44 because of the discount I get through work:

 

I took a couple of hours to notch the frame where the 06 radiator support and radiator interfered with the narrower 09 frame horns. Then today I worked on welding the fender supports back on and moving it up with the fenders to make sure the body lines are good. I fully welded the passenger side support because it's lines were perfect, but I only tacked the driver's side. I have to cut the tacks on the driver's side and raise the front of the fender support a little to get the door gap perfect.

 

Absolutely Bad ***. I would love to see a 6 door with an extended long bed, Maybe a 10 or 12 foot bed. That would be super awesome!

 

Until you try to park it


Looks great! Keep up the good work!

 

Nice progress. I love those wheels. I had those on my 2008, and I really did like them. I wish they still had them as an option. I suppose I could buy some, and actually thought about it. Just haven't gotten the gumption to pursue it.