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I've got the cab and all the sheet metal except the bed temporarily bolted together on my 53 F-100. My plan is to get all the new pieces fitting well and the hood closing nicely before I take it apart for painting. Is there a sequence to fitting these pieces that I should know about to make my life easier? For example, should I tighten up an assembly of inner and outer fenders to deflector before tightening to the cab? Or the other way around? Any advice would be helpful. Right now, I got a very squeeky loosely bolted conglomeration of new repro parts, with new-to-me used parts and patched / repaired pieces. Another question, somewhat related: is it best to paint the pieces separately and carefully bolt it together so not to scartch up anything too badly. Or should I get it tightened up and paint it as one big piece?
What I would do is assemble everything before paint. This way you can see how most of the parts would fit and can adjust anything if necessary. After the pre-fit, I would disassemble everything and "edge" everything. Edging means that you would paint the edges of fenders, doors, hood, etc. I would also paint the insides. After you have edged everything, then reassemble again and paint everything as one unit. This would ensure that all of your color shades and amount of coats match each panel.
For a better idea, visit a local (friendly) body shop to see how they do this.
As far as the order of assembly to get the parts to fit well, it seems like I remember a thread recently where there was a discussion of some of the tips and tricks. You might want to dig into the advanced search feature for the forum. If I remember correctly, the radiator support adjustment and the tensioning rods were done last.
I would also assemble and get all the gaps correct before disassembly and painting. One other thing I like to do after getting it setup correctly and before disassembly is to index each piece to the other by drilling at least two 1/8" holes that will "locate" the correct reassembly. I use short pieces of 1/8" rod during reassembly. Saves a lot of manuvering of parts to get the gaps correct and reduces the chance of chips and scratches.