After tear down we began stripping the sheetmetal down to bare steel. At this point we discovered the truck had more of a rust problem than what we originally thought. Most of the metal was there but it was thin. So we replaced most of the floor, the rockers and steps, the back of the cab, cab corners, front mounts, and the door bottoms.
The cab was sealed with the new Valspar color epoxy primer in red. Then 840 series urethane paint in Viper Red was applied over that. After curing the cab was colorsanded and buffed. Doors and accessory pieces were painted seperately.
Work has also progressed on the chassis. The engine was fitted to the new mounts and appropriate changes were made to the frame. The body was fitted for a clearance and alignment check. Afterwards, the frame was blasted. It was painted with Valspar VP primer and Chassis Black enamel. The engine was painted with 840 series urethane. The engine was mounted in the frame.
Stock suspension is being reinstalled with the first upgrade being a disc brake conversion. Modern rims will require some detailing in red of the brake calipers, rotors, and mounts. The truck will recieve power brakes hidden under the cab. The Classic Performance kit uses the stock pedal and new everything else. The proportioning valve is mounted below the master cylider requiring another rework of the transmission crossmember.
We installed a front sway bar to give the stock suspension more stable turns. Installed the front brake lines. Epoxy primed and bedlined the underside of the cab. We used a tintable bedliner to make it match the exterior color. Then after checking all the fasteners under the cab, we installed the cab onto the frame loosly for now. Then we reinstalled the doors and aligned as best as possible without the fenders.
We added the new steering box using a power saginaw unit from a late 70's truck. The box was mounted outboard of the frame and will be connected to the column using swivel joints. We will have to keep this in mind when choosing rims and tires as it reduces the amount of turn area the wheel has.
A few of the parts came in so we added them. Chrome dipstick, transmission tube, and headers. The Sanderson made headers are probably the nicest ones I've ever seen with a jet hot coating too. They fit perfectly.
Added the plug wires and found a 9inch Ford rear end.
We're currently working on the doors and the firewall.
The side windows are ready for paint and the stainless
firewall is about half done. The stainless is first glued to
a piece of acrylic to give it some added rigidity.
Finished the firewall and the door weatherstrip.
Starting to install the window glass and power windows.
This will be somewhat difficult due to the inaccessability
of the door.
Finished installing the side glass and power window units.
The motors seem a little weak but they go up and down.
We've started working on the dash area and the systems operated from it.
Most of the wiper system is installed. Some of the AC system has been located under
the dash and the compressor was mounted. We are insulating the floor and firewall
for heat and sound reduction. We also located a seat out of a 89 Chev PU.
We cleaned up the rearend. Removed the mounts from the original rear and welded them to the new Ford 9 inch and painted the unit. We still need to install new gaskets and wheel bearings. The axle will also need a lug configuration conversion and some disc brake bracketry.
New gaskets were installed in the rearend and the unit was bolted into the truck.
Installation went pretty good due to careful measurements before the mounts were swaped.
The lower block on each spring was eliminated to drop the axle about 1 inch. It is otherwise mounted in the stock position. We will adjust the ride height after all the weight is on the truck by modifying the shackle configuration.
We installed the main tie rod and pitman arm. Tires were adjusted by eye until it goes in for an alignment. Steering column to box was started but we need another joint.
We fitted the steering column using the new joints and rod.
We decided to refit the front end prior to painting. This gave us an opportunity
to make adjustments to the inner fenders to accomodate the upgrades. From here we will paint all the parts red and reinstall. Also, the seat came back from the upholstry shop.
After fitting the front end again we are spending time with the components to get them smooth and ready for paint. The inner fender panels have had most of the extra holes welded shut and some rust repair. During fitting it was discovered that the radiator would not fit in the original location. So the mounts were moved to the front side of the core support. This gave about an extra inch at the top while still placing the polished top in a position which will be in view. The bottom will be tilted slightly forward to accomodate the pulley system and elecric fan. This entails an entire reworking of the core support bracing.
We prepared most of the front end structure for paint and painted it. The backsides were
coated with tinted bedliner material to give the wheel wells a colored finished look.
Panels were loosly installed to get them into close position. Next the panels will be adjusted to thier final positions and everything will be tightened down.
The front panels were adjusted to thier tenative final positions. The fenders were buffed and the steering column was installed.
Front crossmembers were installed. Shifter linkage was fitted and installed. After looking at another 57 this weekend I've decided to mount the radiator in the stock position minus the electric fan. Once the grill arrives we will install the condenser and fan. This most likely will entail making the fan a pusher configuration. Room both in front and behind the radiator is very limited.
The grill arrived and we installed it. Most of the wiring is complete. The power steering pump is installed. The fan, radiator, and condenser issue is worked out. We once again relocated the radiator on the other side of the core support. This gained about an inch of space inside the engine compartment. The fan was mounted using two straps instead of the large plate that came with it. This gained about another inch. The fan to water pump space is very small but should be adequate. The condenser was mounted on the forward side of the radiator.
Finished organizing the wiring and mounted the fusebox. Completed the floor insulation.
Installed the headlight assemblies. Started to install the rear brakes but found the axle flange to be too large for the new rotors. We will have to have the axles machined.
Finally was able to mount the alternator in a position that might actually work. Started paint work on the hood.
Completed alot of little details. Found a slip yoke for the transmission and installed the driveshaft. Installed the parking lights, bumper, and headlight chrome. Hood hinges and latch are in.
Installed the gauges and steering wheel. Worked on more small stuff and guage sending units.
Installed the gas tank and fuel lines. Painted and installed the hood.
Ran all the air conditioning lines and hoses. Got the axles back from the machine shop but the inner face didn't fit so they were resent out. After return we redrilled the lug holes to the correct pattern. Then we installed the axles. They will still need bearings pressed on but we have an appointment for exhaust and we need wheels. The disc brake conversion was completed. As you can see the truck has way too much rake. That would have looked cool in 1975. We will have to bring the front up a little as the springs are bottoming out. The rear will be lowered to level the truck as low as possible with the suspension we have.
Assembled painted and installed the bed. Installed the battery under the passenger side floorboard. Finished wiring the engine and started setting it up for firing. Tested the fuel lines with gas.
It runs! We finished setting up the engine and fired it. Added the gas tank access cover to the bed. Fixed the front suspension by adding two leaves back in. It's still about a 3 inch drop from factory.
Removed the rear axles and replaced the bearings. Started working on the roll pan. Lowered the rear end by lengthening the shackles. The rear is about 3 to 4 inches lower than stock now.
After investigating the price of rectangular taillights, which are insane, I came up with a light that looks nice. We placed six lenses behind 1 1/2 inch cutouts. Behind those are located six bulbs. We painted the roll pan and tailgate.
We installed the roll pan and ran the rear wiring. Tails, liscense light, fuel pump, and tank sender. Installed the shocks. Intended on getting most of the interior in but was sidetracked at the emergency room with a chunk of metal in my eye. But I did get the door panels done. The bottom portion was sculpted using high density foam and then covered with cloth. The upper portion was just covered so we can mount an armrest and the thickness won't interfere with the door handle operation.
We made and installed most of the interior. Extra time we have allowed for a cool door jamb wire cover made from some washers and a spring.
Installed the rear window.
Installed the windshield. Finished up most of the dash wiring. Tweaked the power windows.
Installed the armrests and switches. Had to add a screw and a pin to each inside door handle because the original door openers were worn and the new handles are not that good. Door panels are complete.
Completed the AC installation. Finished the dash stuff. Installed the headliner. Made a box to cover the AC hoses going into the kickpanel. Interior still needs some trim and visors.
Finished the headliner install and trim. Put in the rear view mirror.
Interior just needs visors, belts, courtesy light, some window trim, and a shift knob.
Pulled the domelight and visors out of an 89 Chev PU. Installed into the 57.
Painted the rear fenders and installed them. Played with wheels and tires forever. Redrilled the rear axles and rotors for the third time since American Racing Wheels only provides the wheels with a Ford pattern. Front tires have more turn radius now but strangely rub the tie rod. So tomorrow they get a set of spacers along with the adapters.
Finished adapting the wheels. Installed the running boards. Detailed the truck. Project complete.
