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06/22/2022 Update
This update contains arguably the largest and most intense stretch of Mater's resurrection. Extensive rust repair, lot's of metal shaping and very delicate manuvering around the inner surfaces of the bed which I decided to preserve. I simply can't paint over the old man's history and hard work that shaped the inside of that bed. It's just my way of paying respect to how hard he must have worked on his farm. I am ecstatic to say that the bed structure is now safely bolted to the back of the truck and it exceeds every one of my expectations. What you'll see in the pics is as much of the dents and history I could save, and very minimal filler to smooth out the welded in panels, shaped to maintain the dented surface they were replacing. yeah, I went that nerdy.
As always, thanks for letting me share this with you guys! https://cimg5.ibsrv.net/gimg/www.for...379f603701.jpg more inside blending https://cimg4.ibsrv.net/gimg/www.for...cfe19f497b.jpg Drivers side metal shaping... the better I get this now, the less I have to use plastic filler later https://cimg3.ibsrv.net/gimg/www.for...0d1f6c46a0.jpg Have I mentioned I needed to do a little metal blending? yeah.... https://cimg2.ibsrv.net/gimg/www.for...beed72f5d6.jpg Even had to carefully betal blend on the inside of the bed sides https://cimg1.ibsrv.net/gimg/www.for...73582a0530.jpg So much careful metal grinding, so little patience https://cimg0.ibsrv.net/gimg/www.for...8c6ae1c62e.jpg More metal blending https://cimg9.ibsrv.net/gimg/www.for...062d853064.jpg Close up of the patch panels https://cimg8.ibsrv.net/gimg/www.for...23f43e8b58.jpg Passenger side patch panels blended https://cimg6.ibsrv.net/gimg/www.for...bf6eca875b.jpg Metal blending on the patch panels done - driver's side https://cimg5.ibsrv.net/gimg/www.for...f4dc78cd3a.jpg Used a little lead here, just because I really like this method of fillilng imperfections, it's really strong. https://cimg4.ibsrv.net/gimg/www.for...8475696008.jpg Starting to reinforce the rear box rail with 1/8 inch steel https://cimg3.ibsrv.net/gimg/www.for...84cbea3652.jpg Metal shrinking to remove metal warping from the heat of the welds. This step removed the iol can effect it developed from all the heat I put into the https://cimg2.ibsrv.net/gimg/www.for...508fdfc18c.jpg Progress on the box https://cimg1.ibsrv.net/gimg/www.for...66ecc74fb8.jpg Rear Box rail reinforced and resurrected from the scrap metal and rot that it really was https://cimg9.ibsrv.net/gimg/www.for...821750824b.jpg The shop foreman and her assistant are doing a little fine tuning before we move this thing into the body shop. Look alive boys! When management steps in swinging hammers you better shape up! https://cimg0.ibsrv.net/gimg/www.for...891a76c264.jpg This patch will eventually be drilled out for the passenger side rear bed mount https://cimg8.ibsrv.net/gimg/www.for...a08b08c985.jpg Here we go... https://cimg7.ibsrv.net/gimg/www.for...ed9f2d9bc3.jpg Prepped and ready for the KBs coating process https://cimg4.ibsrv.net/gimg/www.for...c7e50c283d.jpg Finished metal work, ready to begin the long process of coating and shaping to preserve the history and character of the box. KBS coating will be applied directly to the metal here just like the rest of the truck. https://cimg3.ibsrv.net/gimg/www.for...93f96903e9.jpg Who doesn't winch a 49 F2 bed up in the air on a thursday? https://cimg9.ibsrv.net/gimg/www.for...b30b31cd9a.jpg Getting the bed frame ready to drop the box onto it for final assembly https://cimg2.ibsrv.net/gimg/www.for...42439294f4.jpg Don't drop the box on my foot please... https://cimg0.ibsrv.net/gimg/www.for...4094589ee5.jpg Lowering the box down carefully onto the bed https://cimg1.ibsrv.net/gimg/www.for...2c2216d28b.jpg Lowering the box down carefully onto the bed https://cimg4.ibsrv.net/gimg/www.for...5511709f0e.jpg Easy, easy! https://cimg1.ibsrv.net/gimg/www.for...841533a325.jpg Test fitting the bed - Attempt 1 https://cimg2.ibsrv.net/gimg/www.for...63664a03f9.jpg Test fitting the bed - Attempt 1 https://cimg3.ibsrv.net/gimg/www.for...d9ef533245.jpg Test fitting the bed - Attempt 1 https://cimg6.ibsrv.net/gimg/www.for...96d977b765.jpg Getting the bed ready for another coat of 2K after the test fit https://cimg7.ibsrv.net/gimg/www.for...df4fea6cb8.jpg Another small spot to blend the patch panel https://cimg8.ibsrv.net/gimg/www.for...deef862248.jpg Passenger side smoothing https://cimg0.ibsrv.net/gimg/www.for...92420bb385.jpg Passenger side rear https://cimg6.ibsrv.net/gimg/www.for...d03fc005df.jpg This is where the filler was needed to blend the metal patch work https://cimg7.ibsrv.net/gimg/www.for...845d4bac45.jpg First coat of 2K https://cimg5.ibsrv.net/gimg/www.for...c3a8aa5102.jpg More wet sanding - passenger side https://cimg3.ibsrv.net/gimg/www.for...5a3272834f.jpg Wet sanding the 2K high build primer https://cimg2.ibsrv.net/gimg/www.for...b4f1b88e70.jpg Another angle of the driver's side post repaired with metal and weld. It was the single most meticulous and time consuming thing I have ever done in my life. https://cimg1.ibsrv.net/gimg/www.for...c0719c6199.jpg All metal repair, no filler here https://cimg0.ibsrv.net/gimg/www.for...a3b3487aef.jpg This corner post was carefully reshaped with metal and gentle welding. There is absolutely no filler on these posts, just hourse of hard-headed shaping. https://cimg8.ibsrv.net/gimg/www.for...74371e6051.jpg Anothe rangle of the finished paint on the driver's side https://cimg7.ibsrv.net/gimg/www.for...e5e70bfa4c.jpg Paint work done on the drivers side https://cimg6.ibsrv.net/gimg/www.for...e70d1d59e7.jpg Here's what the RTV layer looks like. Unfortunately, I could not shrink the metal on this panel because I didn;t want to destroy the original paint on the inside. I am sure it will pop back out some day https://cimg5.ibsrv.net/gimg/www.for...e1ee1c9620.jpg The RTV panels to prevent metal on metal rubbing in the future https://cimg4.ibsrv.net/gimg/www.for...5e06240b66.jpg What you're looking at here is a preventative step I took to keep the bed from rubbin gthe back of the cab in the future by masking off these panels and coating them with RTV. We'll see if that was a good idea in a few years. https://cimg2.ibsrv.net/gimg/www.for...b1f1eb02a8.jpg Using the winch to steady the bed https://cimg1.ibsrv.net/gimg/www.for...fb6dc5be97.jpg Trying to carefully drop the bed without hitting the cab https://cimg9.ibsrv.net/gimg/www.for...93cf3ab225.jpg Carefully loweing the bed onto the frame https://cimg8.ibsrv.net/gimg/www.for...d09f66d89f.jpg Nothing cooler than a fat fender Ford on a farm https://cimg7.ibsrv.net/gimg/www.for...7054d45742.jpg Driver's side really looking at home on the farm https://cimg6.ibsrv.net/gimg/www.for...bc760f1b56.jpg Passenger side, really looking cool https://cimg5.ibsrv.net/gimg/www.for...f501ca4585.jpg Pulling Mater out for these pics... I just couldn't get over how much like a completed truck he looks like |
Awesome and awe inspiring! Great work? Thanks for the pictures. Your shop Foreman should be pleased!
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Originally Posted by abe
(Post 20452187)
Awesome and awe inspiring! Great work? Thanks for the pictures. Your shop Foreman should be pleased!
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Nice progress update!
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Originally Posted by pineconeford
(Post 20452951)
Nice progress update!
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Originally Posted by tonyguns
(Post 20453005)
Thanks! I am hoping to make it up to PA truckstock some day to hopefully meet a few folks on here. :)
Just let me know. |
Originally Posted by abe
(Post 20453298)
Tony, it'd be great to have you come to the Central PA Truckstock this fall to meet you and check out your truck. FTE members have 3 cabins that sleep three and at least 1 yurt that sleeps 7.
Just let me know. |
8/24/2022 Update
It's been a busy summer and getting time in the shop has been tricky to say the least. even when I did get some time, it was so stinking hot I just couldn't get a lot done. good news is that the bed floor is absolutely done! as the pictures will tell, I went with something that should look original to the truck, but it's most certainly not wood. Up next will be the rear fenders and tailgate, which should finish out everything that would need paint. I see the light at the end of the tunnel, but it still feels like a train coming my way!
https://cimg6.ibsrv.net/gimg/www.for...d83b38c8f8.jpg This is the bed pulled from my old 82 ford F150 https://cimg7.ibsrv.net/gimg/www.for...d11397b0cb.jpg This is what will become Mater's new bed https://cimg8.ibsrv.net/gimg/www.for...784c7b9921.jpg Stripping off the old 82 ford bed bracing https://cimg9.ibsrv.net/gimg/www.for...5d83035c29.jpg Tons of spot welds, lots of grime https://cimg0.ibsrv.net/gimg/www.for...b93d7664e8.jpg For a heavily used 82, this bed was in fairly good condition https://cimg3.ibsrv.net/gimg/www.for...5d3a3db3b0.jpg The grid I built here lays on top of the box bracing to take up some of the thickness the wood has over the corrugated steel https://cimg4.ibsrv.net/gimg/www.for...74e16364b8.jpg Here's the skeleton for the corrugated flooring https://cimg5.ibsrv.net/gimg/www.for...be94c73f7e.jpg https://cimg6.ibsrv.net/gimg/www.for...db38a18f96.jpg https://cimg7.ibsrv.net/gimg/www.for...dcb7371241.jpg More KBS coating for the box structure https://cimg8.ibsrv.net/gimg/www.for...fe04d898a4.jpg Welding the flooring grid onto the 82 ford's flooring https://cimg9.ibsrv.net/gimg/www.for...b8954c233e.jpg A little more than a spot weld https://cimg0.ibsrv.net/gimg/www.for...ded9ec17e3.jpg Flipping it over to grind down the weld blow through https://cimg1.ibsrv.net/gimg/www.for...3a40cc1d1d.jpg More welds to clean up https://cimg2.ibsrv.net/gimg/www.for...fd280f75d6.jpg Shaping the corrugated flooring to the grid https://cimg3.ibsrv.net/gimg/www.for...33fac87316.jpg KBS coating to ensure a long lasting and rust free existence https://cimg4.ibsrv.net/gimg/www.for...867e24440c.jpg KBS coating almost dry https://cimg5.ibsrv.net/gimg/www.for...c71546c934.jpg shoving the bed in for the first time https://cimg6.ibsrv.net/gimg/www.for...0d4732e4bf.jpg using all my helpers on this one, see them all? :) https://cimg7.ibsrv.net/gimg/www.for...2e6a060b6e.jpg Here's my version of the Lone Wolf 6000 https://cimg9.ibsrv.net/gimg/www.for...9904227b9f.jpg The shop foreman feels like this project needs to be put to bed.... https://cimg1.ibsrv.net/gimg/www.for...53b7a41bfa.jpg Getting the flooring aligned and dropped into place https://cimg2.ibsrv.net/gimg/www.for...b831c12cd6.jpg Looking a lot like it fits... https://cimg3.ibsrv.net/gimg/www.for...90b64e4e74.jpg More tweaking https://cimg5.ibsrv.net/gimg/www.for...1481610458.jpg Seam sealer will keep the weather out of these designed gaps. https://cimg6.ibsrv.net/gimg/www.for...30768a5e8b.jpg The bed floor rests! just a little more touching up and clear coat and it's on to the rear fenders! https://cimg7.ibsrv.net/gimg/www.for...7f56e3ee43.jpg The list shrinks! |
Fully functional, and looks good too. Good work.
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Originally Posted by ternus
(Post 20531431)
Fully functional, and looks good too. Good work.
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Looks good . I'm sure you'll fool lots of casual observers.
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11/17/2022 Update
In now what feels like the home stretch, I've begun tackling the rear fenders, and I'm finding the biggest challenge has been trying to get time in the shop. As for the fenders though, the combination of compound curves coupled with the amount of damage the old farmer inflicted on them has created an incredibly difficult process of trying to repair them with hand fabricated patches while keeping everything in shape. Aside from trying to manufacture parts for the F2/3 and up guys, (posted in another thread) it has been a struggle to get Mater done to say the least, and let's not forget the shop foreman! She is on me like stink on a dung pile...
https://cimg1.ibsrv.net/gimg/www.for...205e63b9fc.jpg Paint/sealer touch up work from the to-do list https://cimg4.ibsrv.net/gimg/www.for...629b4cf7a8.jpg the underside of mater, (requested pic) https://cimg5.ibsrv.net/gimg/www.for...e8f1577062.jpg The (hopefully) final punch list for Mater https://cimg6.ibsrv.net/gimg/www.for...f93689931d.jpg Dents, rust, 60 year old body filler, and a very heavy handed farmer who used Mater hard, mehhh... easy peasey. https://cimg7.ibsrv.net/gimg/www.for...e74001287d.jpg Rust, at every corner https://cimg9.ibsrv.net/gimg/www.for...12ab04befe.jpg The fender on the left is an OEM replacement that must have been from a repair way back when. whomever replaced decided it undercoat it. Unfortunately, the undercoat could not prevent the rust that occurs where the structure bracing is underneath. https://cimg0.ibsrv.net/gimg/www.for...afafe9a026.jpg After looking at how thick the steel is on these fenders, I am convinced these metal braces that cause this rust underneath were probably more destructive than helpful https://cimg1.ibsrv.net/gimg/www.for...6fd452826a.jpg 60 year old filler. Man does this stuff stink when you grind it https://cimg2.ibsrv.net/gimg/www.for...c1375f4ef4.jpg Mater's tailgate having an evap-o-rust bath https://cimg4.ibsrv.net/gimg/www.for...e894ef9e22.jpg Starting the first of the patch panel fabrication https://cimg5.ibsrv.net/gimg/www.for...06138ff2eb.jpg more patch fab https://cimg6.ibsrv.net/gimg/www.for...ec1bbe3b6d.jpg getting the fender bend just right https://cimg8.ibsrv.net/gimg/www.for...661953ef8d.jpg Pie cutting in just the right amount of curve https://cimg9.ibsrv.net/gimg/www.for...c55e716796.jpg more blending https://cimg0.ibsrv.net/gimg/www.for...36bac125fa.jpg the bottom curve taking shape https://cimg3.ibsrv.net/gimg/www.for...4d3b10c508.jpg Pie cutting the top radius. Some people call this lobster tail cutting https://cimg6.ibsrv.net/gimg/www.for...add72dab40.jpg Bracing it in for initial tack welding https://cimg7.ibsrv.net/gimg/www.for...6e1d296ede.jpg More weld prep https://cimg8.ibsrv.net/gimg/www.for...47b84483a5.jpg It's very easy to weld this in and lose the original fender shape... ask me how I know this. https://cimg0.ibsrv.net/gimg/www.for...a1e0c1f0f6.jpg More adjusting of the placement after having to re-cut the curvature in a few spots https://cimg1.ibsrv.net/gimg/www.for...0ba05f66c3.jpg Now let's weld some more, sure... https://cimg2.ibsrv.net/gimg/www.for...6743ab7467.jpg align.... clamps slip... then BZZZZzzt. Cut weld, align clamps, BZZZzzt again... https://cimg4.ibsrv.net/gimg/www.for...936b608896.jpg Maybe this clamp won't slip on me.... nope. https://cimg6.ibsrv.net/gimg/www.for...da86c4d5f2.jpg More pie cutting and re-welding as this fender decided to have a 1 inch growth spurt.... crazy kids. https://cimg8.ibsrv.net/gimg/www.for...3caf2bd28e.jpg BZZZZzzt, BZZZZZt, al tacked in. Yep... this picture doesn't deceive your eyes, it dips(arcs away from level). Each and every one of these tacks had to be cut. https://cimg9.ibsrv.net/gimg/www.for...15ba1fa62c.jpg in through the nose, out through the mouth.... breath.... getting there, except this is just one of three major rust spots to fix on the FIRST fender, and it's only taken weeks to do.... yay. https://cimg0.ibsrv.net/gimg/www.for...f3ee97d689.jpg Looking like an unrusted fender again... if you squint and don't look at the other corners. https://cimg1.ibsrv.net/gimg/www.for...ff2595f6f0.jpg Remember when I posted pics of this being done? yeah... good times. https://cimg2.ibsrv.net/gimg/www.for...a521c243db.jpg The corner where the fender brace bolt comes through welded in and smoothed out https://cimg3.ibsrv.net/gimg/www.for...ba06cde5c5.jpg close-up of the corner https://cimg4.ibsrv.net/gimg/www.for...fdded7c747.jpg More metal fabrication and patch work https://cimg5.ibsrv.net/gimg/www.for...3b96af2437.jpg BZZZzzt, BZZZzzt. I cleaned and welded the inner brace fully to the exterior metal, then patched it. no moisture or dirt will get between them in the future https://cimg6.ibsrv.net/gimg/www.for...ce5d60531f.jpg Hammer and dolly work to get the heavy dents out, Remember though, that I am not ridding Mater of all his bumps and bruises, just the heavy damage. https://cimg7.ibsrv.net/gimg/www.for...0917689637.jpg Tape helps preserve the paint work when you need to mount and remount your fender 387 times while doing your metal work. Yep... tape not necessary if I had just done all the metal work together before painting everything, but in the end, I did it this way because I knew metal work was going to be slow, and I'd need to move the truck outside for extended period of time during the resto process. https://cimg8.ibsrv.net/gimg/www.for...b898a62662.jpg I can say that I have a love/hate relationship with doing lead body work, but it does feel more permanent than bondo. Thanks to my good friend Gene Winfield for the guidance on how to do this stuff right.....nope... we've never met. I watched his youtube video. https://cimg9.ibsrv.net/gimg/www.for...2be9580170.jpg more shots of the leading process https://cimg0.ibsrv.net/gimg/www.for...ec5bf07eaf.jpg more lead filler smoothing https://cimg1.ibsrv.net/gimg/www.for...ff770d8bca.jpg And more lead filler smoothing https://cimg2.ibsrv.net/gimg/www.for...82dd798977.jpg A very light coat of 3M ultra-smooth filler to hide the metal work. https://cimg3.ibsrv.net/gimg/www.for...d81f60df57.jpg Leadding the front corner of the fender. https://cimg4.ibsrv.net/gimg/www.for...7b5fd5a2f8.jpg Another shot of the front corner after applying the lead filler https://cimg5.ibsrv.net/gimg/www.for...ea5208d7df.jpg Lead filler smoothing. This takes probably 5 times the sanding time of bondo, it's just not an easy process, but it really is structural and less likely to every separate from the metal. https://cimg6.ibsrv.net/gimg/www.for...68b9d09e27.jpg More final smoothing of the lead. I think I worked on it 5-6 more hours after I took this pic. all this work, and I have yet to even peek at the passenger side fender yet.... |
Very good....You do an amazing job of repairing some very bad sheetmetal,
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Originally Posted by avf100
(Post 20632662)
Very good....You do an amazing job of repairing some very bad sheetmetal,
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Tony, no pics of the Shop Foreman? Or was she watching from afar? Or on shop cameras in her office?
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