Go Back   Ford Truck Enthusiasts Forums > Older, Classic & Antique Trucks > 1973 - 1979 F-100 & Larger F-Series Trucks
Sign in using an external account
Register Forgot Password?


1973 - 1979 F-100 & Larger F-Series Trucks Discuss the Dentsides Ford Truck

Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
  #1  
Old 08-29-2009, 04:40 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
My GT500 truck build thread...picture intensive!!!!

As most of you know by now, I am in the process of building my truck into what I think Carroll Shelby would have done if he had actually made one. Please keep in mind that this is my interpretation of what it might be, and is in no way a basis for any kind of "factory correctness."

I have been making some progress, but there is still a lot left to do. Originally I was going to keep the details of the process to myself, but I figured what the heck...let everybody see, and if somebody wants to use my ideas, so be it.

The most labor intensive part has been the inboard headlights, as were seen on the early '67 GT500s. Luckily, the '73-'75 grille is a great platform to start with. This is what original GT500 inboard lights look like.
Click the image to open in full size.

As you can see, the inboard lights are the same as the regular headlights, and they use the same retainer rings.

This is my interpretation...
Click the image to open in full size.

My lights are also identical to the regular headlights and share a similar type of retainer ring.

So how did I do this? Here are the steps.

1. Bought two replacement headlights from AutoZone: Sylvania 2D1.

2. Went to Lowe's and found PVC pipe that would fit a 6" standard headlamp: NDS L6P07 6" to 4" reducer.
Click the image to open in full size.

You can also use a 6" collar, which does not have the taper. If I were to do this again, I would probably use a straight collar piece.

3. Place the headlamp on the collar and mark cutouts for the locating tabs. Be sure to keep the bulb level and hold it in place as you make your marks. I taped mine.
Click the image to open in full size.

4. Cut out the slots for the bulb tabs. I used a hack for the sides, then cut out the rest with my dremel and a side cutting bit. This doesn't have to be precise, but you do want to make them deep enough for the bulb to seat properly.
Click the image to open in full size.

5. Use the large end of the PVC pipe and a fine point Sharpie to mark where to cut on the grille. Here are the measurements I used to position the pipe and mark mine:

-1 3/8" from inside center of grille on center horizontal bar
-1 1/8" from inside top of grille
-11/16" from inside bottom of grille

6. From the marks you made on the grille bars, use a straightedge to transfer the outsides of the marks to the top and bottom of each bar. This way you will have a guide to help you cut it straight and keep the angles right. I didn't do this, and I paid the price in hours of trimming and fitting, retrimming and refitting...uuuuuuuugggggghhhhhhh...........

7. Cut the grille bars on the inside of the marks you made. You can always fine tune and take a little more out, but you can't put any back in! I used a hack and I had to take the blade off, feed it inside the bars, and put it back on to do the cutting on the very top and bottom bars. For the center bar (once I had room), I used a Dremel with a cutting wheel...much easier and much faster. Here's what the grille will look like after cutting.
Click the image to open in full size.

8. This is where the fitting and trimming come in. You'll have to keep putting the PVC reducer in and and taking it out until you get a snug fit that doesn't distort the bars. In other words, you should have to apply a little bit of pressure to get it in, but you shouldn't have to crank on it. I installed the cut grilles back in the grille shell so they were being trimmed in the position they would ultimately be installed in permanently. Why? If I got everything to fit well outside the grille shell but something got distorted in the process, the inserts would no longer fit right...so I did my fine tuning there. I used a sanding barrel bit on my Dremel to trim areas on the grille that didn't fit very well.
Click the image to open in full size.

9. Once I got everything to fit properly, I taped the headlights in position, installed the new headlight "buckets" in the grille inserts and rotated them until the logos on the lights were level and even, and pushed on two '70s Dodge van headlight retainer rings. I could have used original Ford rings, but the Dodge rings are thicker on the outside, which helps to cover the bulb cutouts (especially if you cut them a bit deep!) They are a heck of a lot easier to find, too...around here, at least. I had to fiddle with the positioning so they were both in the same position (opposite) and there was enough room to install mounting pads for them. I then taped them in place, removed the entire bucket/bulb/ring assembly from both sides, and using the bottom of the retainer ring mounting tabs, marked the position for each of the retainer ring mounting pads with a straight line.

MORE TO COME TONIGHT...GOTTA TAKE A BREAK AND FINISH TRIMMING THE LAWN...

Next, making the mounting pads.
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #2  
Old 08-29-2009, 04:55 PM
peganit2's Avatar
peganit2 peganit2 is offline
Elder User
 
Join Date: Feb 2008
Location: Davison, Mi.
Posts: 999
peganit2 is starting off with a positive reputation.
Thats cool. Excellent ingenuity. What else are you gonna do to the truck?
__________________
Project truck "Dirty Beast" BBF Highboy

"Make things Simple, Not Simpler" - Albert Einstein
Reply With Quote
  #3  
Old 08-29-2009, 06:21 PM
77red4x4's Avatar
77red4x4 77red4x4 is offline
Senior User
 
Join Date: Dec 2005
Posts: 398
77red4x4 is starting off with a positive reputation.
Interesting idea. Hope it turns out well for ya.
__________________
Bondo is an art...and I'm no artist.
Reply With Quote
  #4  
Old 08-29-2009, 07:37 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
OK...on to the next step.

10. Making the mounting pads for the headlight retainer ring.

I got a piece of 1/2" X 1/2" L-channel aluminum for the job. I cut six 1/2" pieces out of it (3 per side) using the hack and a bench vise. Then I drilled a 1/8" hole in one side of each piece for the machine screws and nuts that hold them to the PVC buckets.

Using the guide lines I marked earlier, I held each of the aluminum brackets up to the buckets and used a sharpie to mark the mounting holes in the PVC. I drilled the holes out with the same 1/8" bit, then installed each of the brackets with the machine screws and nuts.

Next, I reinstalled the headlights and rings on the buckets, lined up the rings' mounting tabs with the aluminum brackets, and marked the holes for the mounting screws. I drilled them out with a #9 drill bit, and threaded the holes with the #10 black trim screws used to hold the retainer rings.

Finally, I used a pair of tin snips to round off the mounting brackets and trim off any excess, then hit them with the sanding drum on my Dremel. DONE! Unfortunately, since I was doing these as quickly as possible, I didn't get any pics of the process, but it is pretty straightforward. There are pics of the setup in the next section.

11. Bucket to grille assembly

For this, I inserted the buckets (with headlights and rings on them) into the grille inserts, installed the grille inserts in the grille shell, and lined them up so the logos on the bulbs were even. I used a yardstick to level the bulbs vertically, and eyeballed the horizontal alignment. I carefully marked the position of the buckets so I could keep them lined up properly during the assembly process, then removed the bulbs, rings, and grille inserts. I sanded the old paint off of the grille inserts where the epoxy had to bond.

To bond the PVC to the plastic grille, I used Car-Go plastic repair epoxy putty. It's easy to mix, easy to form, sets quick, bonds great, and smoothes very well with only water and your finger...as long as you do it before it sets, obviously. Boy, does it stink, though....

I did one section at a time, being sure to keep all of the alignment marks where they belonged. Note the retainer ring mounting brackets in the pics below:
Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.

Once I had all of the joints done, I let them cure out in the shed for a few days.

12. Shaping and painting

When the epoxy was cured, I again used my Dremel and the barrel sanding bit to refine the joints and remove the excess epoxy. That, combined with 220 grit sandpaper to round off the sharp corners, gave me a good finish.

I painted the new grilles white, allowed them to dry, and then used a brush to apply Testors #1149 flat black enamel (yes, model paint!) to the retainer ring mounting tabs and the mounting brackets. That, combined with the black screws, makes them disappear in all the black on the radiator and core support.

13. Final installation

I assembled all of the grille pieces and installed the inserts in the grille shell using stainless steel screws.

Look closely...can you see the retainer ring mounting tabs, brackets, or screws?
Click the image to open in full size.

COMING UP...THE NEW HEADLINER.
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #5  
Old 08-29-2009, 07:50 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
Quote:
Originally Posted by peganit2 View Post
Thats cool. Excellent ingenuity. What else are you gonna do to the truck?
Can't give away all of my ideas...heheheheh

I've already done a ton of work mechanically, a good amount of body work/ part replacement, paint/undercoat, rust repair, etc...

I'm moving right along, with the minor inconvenience of needing a new bed and tailgate...
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #6  
Old 08-29-2009, 08:21 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
Update

HEADLINER

Realizing that my old headliner had seen better days, I decided to try continuing the Shelby theme on that. For quite some time, I had struggled with how to do it, materials, etc. So one day I decided to quit thinking about it and get to doing something.

I went to Lowes and found some wallboard that had a laminated white finish on one side. I figured that would be perfect, so I had them cut the material to the dimensions I needed (54" x 29") and I was on my way back to the house.

Using the old headliner, I traced the pattern out on the new board and marked the hole for the center screw, then cut it with the jigsaw and a scroll blade. I cleaned up the edges with 220 grit and bingo bango...new headliner, already white...(with crud on it from sanding...sorry)
Click the image to open in full size.

But then I thought...I can do better than that. A white headliner on a white ceiling is a bit anticlimactic and sterile. So I decided to blow up a snake.

I traced a picture of a Shelby snake on another piece of the wallboard, colored it in with a Sharpie, and badda bing!
Click the image to open in full size.

I cut it out, sanded the edges smooth and round, blackened them with a Sharpie, and...
Click the image to open in full size.

Put the headliner and the cutout together and what have you got?
Click the image to open in full size.

Since then, I have also stripped and repainted the headliner fastening strips. They were black, latex white, and rust with rusty screws. Now they are cast aluminum gray metallic, clearcoated, and have stainless screws. I'll get pics of those up when the headliner actually goes in...which won't be until I get to painting the inside of the cab. The dash is already done, so maybe I won't have to wait THAT long...

Well, until the next update, enjoy, and I'll see you around the site!
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #7  
Old 08-29-2009, 08:26 PM
peganit2's Avatar
peganit2 peganit2 is offline
Elder User
 
Join Date: Feb 2008
Location: Davison, Mi.
Posts: 999
peganit2 is starting off with a positive reputation.
That all looks good. But I can see the factory mounting tabs on the grill.
__________________
Project truck "Dirty Beast" BBF Highboy

"Make things Simple, Not Simpler" - Albert Einstein
Reply With Quote
  #8  
Old 08-29-2009, 09:59 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
Quote:
Originally Posted by peganit2 View Post
That all looks good. But I can see the factory mounting tabs on the grill.
I didn't say anything about the FACTORY mounting tabs for the grill...I meant the mounting tabs for the new headlights and rings...


Quote:
Originally Posted by Bowtie_Schmowtie
Look closely...can you see the retainer ring mounting tabs, brackets, or screws?


Thanks for the compliment, though.
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #9  
Old 11-14-2009, 12:32 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
UPDATE!!

Headliner installed...

Click the image to open in full size.

I know, the metal around it looks crappy right now, but I just HAD to get it up there and see what it looked like!

Finished door panel scheme...at least for now...

Click the image to open in full size.

And the dash with the new Grant stainless nostalgia wheel and Cobra horn button. I LOVE IT!

Click the image to open in full size.

Makin' progress here...long way to go still, but gettin' there.

I have now acquired four pretty decent "dog dishes" for factory wheels and a factory aluminum air cleaner, which I have modified to a dual inlet with a polished lower section and a cast iron finish painted lid. Currently working on an engine ID plate for the lid, also.
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #10  
Old 11-14-2009, 01:40 PM
79FordBlake's Avatar
79FordBlake 79FordBlake is offline
Posting Guru
 
Join Date: Feb 2007
Location: Wingo, Ky
Posts: 1,686
79FordBlake is starting off with a positive reputation.
Dang why couldnt I think of that. All of it looks very nice.
__________________
'78 Bronco, 351
'79 Bronco, 400
'79 F150 302, c4, custom, lwb, 4v 600 Edelbrock, Edelbrock performer intake. .030 over, 278 Crane cam.
'92 F150, 302
Reply With Quote
  #11  
Old 11-14-2009, 06:26 PM
Tees77f150's Avatar
Tees77f150 Tees77f150 is offline
Posting Guru
 
Join Date: Nov 2008
Location: Halifx Pa
Posts: 1,647
Tees77f150 is gaining momentum as a positive member of FTE.
Thats cool! You remind me of my grand father when he was alive, if it wasn't broke, he was still gonna fix it! He would take his cars, late 50's, or early 60's Fords and but ground traps off of the back, reflectors on the center of the wheel covers, big red foam ball on the antanna etc, etc,. My grand mother would just shake her head as he would wash and wax it all day Saturday, then turn around and wax it again on Sunday afternoon because he was bored. He was hard core Turtle wax man back in the day too.

But anyhow, I like what you do, with your ride, I am a stock original kinda guy, but it still neat to see all of your creative ideas bear fruit. Good luck, and keep up posted in your upgrades, I think its neat!!
__________________
Harold
Molly Hatchet: Flirtin' With Disaster
1977 F150 Custom Explorer
300 I6, C4, Copper Metallic, built 3/77 Michigan plant.
http://i540.photobucket.com/albums/g...ine/truck5.jpg
Reply With Quote
  #12  
Old 11-14-2009, 06:43 PM
Bullitt390's Avatar
Bullitt390 Bullitt390 is online now
Certified Thread Hijacker
 
Join Date: Aug 2001
Posts: 12,224
Bullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud ofBullitt390 has much to be proud of
joshjones.thewelder
Quote:
Originally Posted by Bowtie_Schmowtie View Post
Headliner installed...

Click the image to open in full size.
Now THAT is schweet!

Josh
__________________


2006 F250 XLT 6.0 PowerStroke Diesel 4X4: SRL Custom Tune Atlas 40 FICM Rotella 0W40 DASHBOSS Ford VCM II IDS Custom Y-Pipe Fabrication
Reply With Quote
  #13  
Old 11-14-2009, 08:39 PM
1975StroppeBaja's Avatar
1975StroppeBaja 1975StroppeBaja is offline
Postmaster
 
Join Date: Apr 2006
Location: WV
Posts: 2,936
1975StroppeBaja is a splendid one to behold1975StroppeBaja is a splendid one to behold1975StroppeBaja is a splendid one to behold1975StroppeBaja is a splendid one to behold1975StroppeBaja is a splendid one to behold1975StroppeBaja is a splendid one to behold
This is a really cool project! Lookin' good!

Subscribing
__________________
Jason - 2004 F250 XLT Sport CC, 5.4L, 4.10LS, AT, JBA's & SPD y-pipe

Click - My Super Duty Tech Articles
1975 Baja Bronco Project
1984 Ranger 4x4 R.I.P Nov 2007
Reply With Quote
  #14  
Old 11-14-2009, 09:23 PM
Bowtie_Schmowtie's Avatar
Bowtie_Schmowtie Bowtie_Schmowtie is offline
Elder User
 
Join Date: Jan 2009
Location: Western N.C.
Posts: 738
Bowtie_Schmowtie is gaining momentum as a positive member of FTE.
Thanks for the support, fellas!

Tees, I will be a chronic waxer when it all gets done.

Still a lot of decisions to be made and a lot of resources to be found, though.

Currently on the lookout for a nice pair of gray buckets, and gotta decide on wheels.

What do you think about these options?

1.) Wheel Vintiques model 41 painted rallye

2.) Wheel Vintiques model 43 chrome rallye

3.) aluminum five-hole bullet rims (junkyard has 4 on an '88 van)

4.) stock steel wheels painted white with cast iron gray painted dog dish style center caps OR

5.) stock steel wheels painted white with chrome lug nuts and short recessed chrome center caps (think factory '64 Thunderbolt style, but with some dress-up)
__________________
Quote:
Originally Posted by Bob Gervais View Post
Wes, don't judge man. My milkshake brings all the boys to the yard.


'78 John "Icepick"...'73 F100 Custom "Eddie" 360 2V, 3 in the floor...'90 F150 XLT Lariat "Bruce" 4.9 EFI, 5 in the floor
North Carolina Chapter Member
Reply With Quote
  #15  
Old 11-15-2009, 01:16 AM
projectbad78's Avatar
projectbad78 projectbad78 is offline
Elder User
 
Join Date: Mar 2008
Posts: 738
projectbad78 is starting off with a positive reputation.
got a pic of the front at an angle and not so close?
__________________
http://i33.tinypic.com/wi7qx1.jpg

1978 F100 custom
351W
-offy intake
-'brock carb
C4
Reply With Quote
Old 11-15-2009, 01:16 AM
 
 
 
Reply

Similar Threads
Thread Thread Starter Forum Replies Last Post
Best way to strip clearcoat off wheels? Bowtie_Schmowtie 1973 - 1979 F-100 & Larger F-Series Trucks 20 03-07-2010 05:54 PM
2009 FTE Online Championship ROUND NINE ENTRY THREAD Greywolf General Automotive Discussion 61 10-10-2009 01:10 PM
2009 FTE Online Championship ROUND SEVEN ENTRY THREAD Greywolf General Automotive Discussion 56 08-19-2009 12:25 AM
Pics of my new dash colors and continuing grille work Bowtie_Schmowtie 1973 - 1979 F-100 & Larger F-Series Trucks 20 08-13-2009 08:51 PM
2009 FTE Online Championship ROUND FIVE ENTRY THREAD Greywolf General Automotive Discussion 43 07-16-2009 06:49 PM


Go Back   Ford Truck Enthusiasts Forums > Older, Classic & Antique Trucks > 1973 - 1979 F-100 & Larger F-Series Trucks

Tags
1999, 2d1, build, f250, fit, ford, grille, gt500, headlights, replacement, shell, steps, sylvania, thread, trimming, truck

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump


Participate In The Forums

Create new posts and participate in discussions. It's free!

Sign Up »





All times are GMT -5. The time now is 01:16 AM.


Powered by vBulletin® Version 3.8.7 AC1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Advertising - Terms of Use - Privacy Statement - Jobs
This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. Ford® is a registered trademark of the Ford Motor Company.

vbulletin Admin Backup