This is dedicated to everyone wanting to comment on things they have found on their trucks that have left you flabbergasted and confused as to what the thought process was of the previous owners when you decided to repair, replace, or update something on your truck.

I started on the power steering install for my 65 F-100. With the exception of the pressure and return hoses, I have everything I need. The original column came out easily, and I dropped it off at the steering column shop nearby to have it shortened and fresh bearings installed. With the front end on jackstands I crawled underneath and intended to disconnect the right tie rod from the pitman arm. There's a substantial build up of road grime on everything under there and can't see the ends of the cotter pin, so I grab the soda blaster and do some seriously needed cleanup on the suspension and steering components.
With everything clean and armed with my needle nose pliers I go to pull the cotter pin, only problem is, I still can't see it. Now I'm confused. Giving it a closer look is when I realize someone used a plain flat nut instead of the correct castle nut, and to replace the cotter pin, they did an excellent job of WELDING the top of the nut to the exposed thread of the shaft. Not just a tack weld in a spot or two, they welded it in a full circle.
I guess my new die grinder gets to be tested on my next day off.

 

They didn't want it to fall off!

 

"I'll never have to take it off."

 

I guess I should be glad they didn't buy tires with a lifetime warranty, heheh...

 

Yep it's fixed

 

Well, with about 20 minutes worth of careful grinding the welding was removed. As I ground away I figured out what they did. Someone had used a 3/4 - 1 ton style lug nut backwards, with the flat side towards the pitman arm and the conical side up. It took less time to remove the manual steering gearbox than it did to undo the tie rod/pitman arm connection.

progress...