Part 2 of 2.... finish Bedside Stakes and Rails rough in
OK, here's the final prep.... Part 2 of 2 of the Bedside Rails and Stakes.
The first couple of pics show the general layout of the rails and all clamped in place so I can now drill the holes to fasten them all together. I'll use ss screws, nuts and washers. I'll also put a washer between the rail and the stake to allow a some air gap to help prevent and moisture being trapped between the wood.
https://thefactoryfiveforum.com/atta...2&d=1711214365
https://thefactoryfiveforum.com/atta...3&d=1711214403
In the next pic below, you can see how the FFR Bed side Stake Pockets will cover the wood stakes. With all this mockup, it will allow me to epoxy the Stake Pockets in place on the Bed Side for final bodywork and paint.
https://thefactoryfiveforum.com/atta...4&d=1711214438
To hold the stakes in place, I'll drill 2 holes into the stake from the inside bed side. On the backside of the stake, I'll counter sink a T-nut. I'll show details later once I'm finished the mockup.
https://thefactoryfiveforum.com/atta...5&d=1711214468
Mark
Bed Rail and Stake fasteners
I was asked in a PM to show the hardware I plan to use.
For the Rail to Stake, here's the inside view:
https://thefactoryfiveforum.com/atta...8&d=1711370214
Rail to stake outside view with acorn nut:
https://thefactoryfiveforum.com/atta...7&d=1711370192
Bed Side to stake inside view
https://thefactoryfiveforum.com/atta...0&d=1711370262
T-nut on the outside hidden(blind side) by the Stake Pocket. I still need to counter sink the T-nut so it's flush with wood stake
https://thefactoryfiveforum.com/atta...9&d=1711370246
Mark
Engine bay side vents installed
Yesterday was spent taking the fenders and running boards off as there is no longer a need for them now that they are fitted and ready for final body work.
This also allowed me to remove the engine side covers to install the louvered vents. I first made a template of the vents and tapped the opening. I used a jig saw to cut out the opening and flat file to clean up the cut.
Lewis.... when you come to get the oil cooler and fan, I'll give you the template if you decided to order the same vents
Next, I used some popsicle sticks for the gap between the side panel and the backside of the vents. Taped them in place both front and back.
https://thefactoryfiveforum.com/atta...7&d=1711541969
https://thefactoryfiveforum.com/atta...8&d=1711542009
https://thefactoryfiveforum.com/atta...9&d=1711542046
Then I removed the vent tabs that will hold the vent in place. I used 40 grit on the fiberglass and the backside of the tab. I drilled three holes in each tab to help with a secure bond (copied Paul's process) and cleaned both surfaces with acetone. I used the 3M epoxy used in earlier posts to set the vent tabs and clamped in place.
https://thefactoryfiveforum.com/atta...0&d=1711542079
https://thefactoryfiveforum.com/atta...1&d=1711542107
Now, I can start the bodywork on the radiator cowl, hood, cab and doors while it's still all mounted on the chassis. Once I get the panel's surfaces matching, I can then remove all the fiberglass from the chassis for final bodywork, primer and paint.
This is bitter sweet for me and it's the first time doing body and paint on one hand and nearing the finish line on the other.
Stay tuned,
Mark
Tear down of the the body off the chassis
Over the weekend, I tore down the body off the chassis and I'm now diving headfirst into body prep.
My first focus will be the cab and removing the LizardSkin that didn't stick to the inside of the cab. This time around, I'll grind to clean and scuff the interior fiberglass then wipe down with acetone before reapplying the two LizardSkin products (i.e., Sound and Heat)
https://thefactoryfiveforum.com/atta...0&d=1711974366
https://thefactoryfiveforum.com/atta...1&d=1711974387
I'll also cleanup the wiring
https://thefactoryfiveforum.com/atta...3&d=1711974414
https://thefactoryfiveforum.com/atta...4&d=1711974440
After basic body panel prep for initial filler and flat sanding, I'll start the various primers and final sanding before paint.
I've never done body and paint before, so it's a learning experience for me. I have a lofty goal to be complete with paint and body back on the chassis by end of May, 2024. We have a trip planned for the first week of May.... so, I have approx 7 weeks to meet my goal. Then my next goal will be the truck is complete before we go on our next trip mid to end of June.
Stay tuned,
Mark
Cab interior covered with two products for sound, vibration and heat
After cleaning and scuffing the cab's interior, I changed my mind on the LizardSkin. I had other sound and heat options from other builds I've done. And to be very honest, after my bad experience with LizardSkin peeling off and my plan to glue my interior cover to the side walls.... well, I was very concerned about the interior side cover not staying in place because of my fear LizardSkin would fail over time.
I first cleaned all the interior surfaces again with Acetone. Then proceed with a Dynamat type butyl rubber backed by aluminum foil.
https://thefactoryfiveforum.com/atta...1&d=1712319904
Then I covered most of the foil backed butyl rubber with this product.
https://thefactoryfiveforum.com/atta...2&d=1712319948
This material is about 1/2" thick, heavy dense foam backed by a very sticky adhesive. Both the butyl rubber and foam will be great for sound, vibration and heat.
https://thefactoryfiveforum.com/atta...3&d=1712319968
I also covered the back panels with the foam mats.
https://thefactoryfiveforum.com/atta...4&d=1712320017
Lastly, I cut 1/4" lauan plywood to fit the roof that I'll cover with the diamond padded vinyl for the finish look and a fiber material for the sides. I'll add this after painting. Then I'll set the completed interior cab back on the chassis. It's much easier to do the interior while the cab is off the chassis.
https://thefactoryfiveforum.com/atta...5&d=1712320051
Some of you may be wondering why the gap in front of the plywood. Well, you may recall from earlier posts I made an overhead gauge panel that fit tight to the cab's roof.... so, I had to leave room for the gauge panel to fit
Stay tuned,
Mark
Truck Cab base frame made and installed
Since I'm doing my Cab's body work and paint off the chassis, I had to build a frame system for the bottom of the cab to stiffen it up, with the cab to be up off the ground and be able to move it easily by myself.
Came up with the design below
https://thefactoryfiveforum.com/atta...7&d=1712576961
I didn't want to drill holes in the cab's base, so I used fender washers to hold the cab to the wood frame
https://thefactoryfiveforum.com/atta...8&d=1712576985
In the picks below, note the long front to back runners.... they are 30" apart, the same as the moving dolly I have. I simply clamp the dolly to the frame to hold in place while I roll the cab where I want it. Then, I can unclamp it, lift the front of the cab to tilt backwards and simply remove the dolly for a firm cab stance on the ground for sanding, etc.
https://thefactoryfiveforum.com/atta...9&d=1712577001
https://thefactoryfiveforum.com/atta...0&d=1712577026
When I'm done with body and paint, I'll place the cab on my lift's arms to complete the interior while comfortably standing inside the cab. I'll also use the lift to lower the cab back on the chassis.
More to follow,
Mark
Stack Pocket mounting to Bed Sides
During my body work on the bed side panels, I had to add some "parts". You might recall that I bought from FFR the Stake Pockets option. Well, by installing the pockets you hide the rear mounting area and, thereby, can't access the mounting button head screw. So, my fix was to install a couple rivnuts to each of the rear side panels so I can install the screws from the inside vs the outside.
Since the side panel has pretty thick fiberglass and the upper hole also had the ss wrap, the standard rivnut wouldn't work, i.e., not enough grip area was exposed for proper rivnut expansion..... so, I found this type of rivnut which worked out great.
https://thefactoryfiveforum.com/atta...9&d=1713184315
In the next pic, I bonded the stake pocket to the bed side with 3M's High Strength Repair Filler (HSRF). I scuffed up the bed side and stake pocket mounting surfaces with 40 grit and applied the HSRF to the stake pocket and pressed on the pockets to the bedside. 30 min's later, I was cleaning up the HSRF that squeezed out. I'll show the finished panel later in another post.
https://thefactoryfiveforum.com/atta...0&d=1713184342
More to follow,
Mark
Get'n back into the saddle
The new house move has light at the end of the tunnel. We have our move to Tennessee complete and I'll have a new shop area of ~1000 sq ft. All my tools and '35 Truck "stuff" will be moved in this week. You'll note I have the floors coated and now ready for the work to begin.
Here's a quick peek:
https://thefactoryfiveforum.com/atta...6&d=1724069521
https://thefactoryfiveforum.com/atta...8&d=1724069579
https://thefactoryfiveforum.com/atta...7&d=1724069554
Closeup of the floor coating:
https://thefactoryfiveforum.com/atta...9&d=1724069602
It will be slow moving to get to work on the truck as I have to unpack all the "stuff" and set it up right.
Stay tuned, Mark
Back in the saddle and ready to complete the build!
Well, the day finally arrived when I've completed all the house updates. I then focused on the shop, i.e., unpacked all the boxes, built a couple workbenches, hung "stuff", connected air compressors/lines, and laid out all it '35 parts. In addition, I installed lots of extra LED lights around the primary work areas. I'll also be buying a scissor jack.
I'll be cleaning up some wiring and then it's mostly body work and painting. I'll document all that as I progress. My goal is by Spring 2025 it's complete.
A few pics show the completed shop.
Mark
https://thefactoryfiveforum.com/atta...6&d=1736859413
https://thefactoryfiveforum.com/atta...7&d=1736859441
https://thefactoryfiveforum.com/atta...8&d=1736859486
https://thefactoryfiveforum.com/atta...9&d=1736859522
Interior start and cab preinstall questions??
To finish my build, I need to complete body and paint (along with my interior)..... but, I need the weather to be warmer to do all the prep/sanding outdoors so I don't "dust up" the entire shop. So, I'm focusing my "winter time" to wrap-up the interior as much as possible. I shared a few pics below of my start, i.e., Carpet and Speakers. I'm upgrading my carpet from FFR's supplied carpet (I'll use FFR carpet as a template, after I fit it, to cut the new carpet). It's better carpet and more "period correct". I started on the back panel where I have a pair of tri-axial speakers and a pair of subwoofers. I also have speakers for the cab front I'll show later.
However, I do have questions on what I can do before the CAB is put back on.... examples, can I install the dash, the seatbelts/shoulder belt brackets to the roll cage, etc. I'd like to also install the roof liner before the cab is put in place??
INPUT needed to the above questions. Any thoughts, cautions, got-yas most welcome!
Thx Mark
BACK PANEL:
https://thefactoryfiveforum.com/atta...7&d=1737897427
https://thefactoryfiveforum.com/atta...8&d=1737897459
Passenger Side floor:
https://thefactoryfiveforum.com/atta...9&d=1737897493
No on Dash preinstall prior to cab install
OK, I just answered one of my questions..... you can't install dash before the cab as the dash bolts to the cab flange along the door opening and preventing the cab slipping behind the dash flange.
Mark
Front and rear dash prep install
While installing the interior, I had to complete all the wiring, e.g., speakers, security alarm and my front and rear dash cam.
The pic below is the unit being installed. The rear camera plugs into the main front camera. Both front and rear camera views are displayed on the color lcd monitor on the backside of the front camera. Also, the main mount has GPS and the GPS position is also recorded. This unit was highly rated during my research.
Mark
https://thefactoryfiveforum.com/atta...2&d=1738160666
1935 Tenn Tag and Registration
I just wanted to share the end results of me registering and titling of my '35 Truck.
As the pic shows, my tag and registration, Tennessee registered and titled my truck as a 1935 Ford F5R. I bought the '35 License Plate/tag off eBay and they used it. And since it's an antique, it's a permanent tag with NO yearly registration fee. Also, they used FFR Ser # for my VIN. Lastly, no inspection in any way shape or form was required!
I couldn't have asked for anything better. :D
Mark
https://thefactoryfiveforum.com/atta...8&d=1738180071
Interior console and seat belts installed
I'm getting the interior buttoned up with the Console I made installed (along with all the internal electronics) and seat belts installed. I still have the outside side carpet to install along with the metal door opening "scuff" strips. The two sets of wires coming out of each side of the console are for the seats lumbar pump and the electric seat heaters (requirement of the wife). You'll note the control buttons for the lumbar, seat heaters, door pwr windows, etc are all mounted in the console. Below the radio is the HVAC auto control.
Thx Mark
Here's a few pics of the interior:
Drivers side:
https://thefactoryfiveforum.com/atta...5&d=1738416017
https://thefactoryfiveforum.com/atta...4&d=1738415984
Passenger side:.... note the subwoofer amp attached to the rear panel. It will also attach to the cab once installed.
https://thefactoryfiveforum.com/atta...6&d=1738416054
https://thefactoryfiveforum.com/atta...7&d=1738416081
https://thefactoryfiveforum.com/atta...8&d=1738416110
A great way to bleed brakes and hydro clutch
I'm sure many of you know and/or use this Motive Products device. For those that don't, you just select the cap that fits your brake fluid container(s), fill the Motive jug with brake fluid, pump to put positive air pressure in the jug to ~5-10psi. Then just open the bleed valve on each brake caliper or clutch throw-out bearing bleed hose. Keep open until all air bubbles are gone and you'll have perfect, 1-man, blead brakes.
Once you use this, you'll never go back to the "old" way to bleed brakes.
Mark
https://thefactoryfiveforum.com/atta...3&d=1738680058
https://thefactoryfiveforum.com/atta...2&d=1738680029
Stage 8 Header Bolts installed
After several engine heat cycles, I decided to re-torque the Stage 8 Header Bolts and install the lock tabs to prevent them coming loose.
The next three pics below show the locking tabs and lock clips followed by the bolt head without the lock tab/clip
https://thefactoryfiveforum.com/atta...4&d=1738680088
https://thefactoryfiveforum.com/atta...5&d=1738680110
https://thefactoryfiveforum.com/atta...6&d=1738680127
The last two pics show the lock tabs and clips installed
https://thefactoryfiveforum.com/atta...7&d=1738680146
https://thefactoryfiveforum.com/atta...8&d=1738680162
Weather is starting to warm up which will allow me to start body work outside.
Stay tuned, Mark
Tach Signal for Dakota Digital tach with Coyote engine
I'm using Dakota Digital gauges/Tach with my Ford Performance crate engine and ECU. I tried to pickup the tach signal from one of the coil pack neg (-) wires and the tach was very sporadic (i.e., sometime showing the correct RPM and other times jumping around and/or freezing).
After reading many threads, I determined I needed a tach signal adapter to pickup a tach signal from the Coyote's ECU/PCU. There are several adapters on the market, but I chose the AutoMeter unit as it seemed to be the most popular.
The AutoMeter unit has 4 wires, i.e, RED = +12v in from the ECU/PCU, Red/Green stripe = +12v out to the coil control packs, Black = ground and Gray = Tach Signal output. Here's a pic of the AutoMeter Tach adapter
https://thefactoryfiveforum.com/atta...1&d=1739539072
To start, you have to fine the purple wire off the ECU/PCU that feeds all 8 Coil Packs. This main Purple wire is fed from the fuse shown in the picture below. This fuse bank is part of the ECU/PCU kit.
https://thefactoryfiveforum.com/atta...0&d=1739538347
After I striped back the wire harness protective tape and seeing the purple wire I cut it to splice in the Red and Red/Green wire from the Tach Adapter. To ensure I cut the correct wire, I put a multi meter to make sure I had +12v from the purple wire, then pulled the fuse to ensure the power was off. After determining I had the correct wire, I installed a Female connector the the ECU/PCU side and a Male connector on the Coil side of the purple wire.
https://thefactoryfiveforum.com/atta...2&d=1739539096
Per the instructions, the red wired from the tack adapter (male connector installed) plugs to the Purple wire from the ECU/PCU side. The red/green wire from the tach adapter (female connector installed) plugs to the purple wire feeding the Coil Packs.
https://thefactoryfiveforum.com/atta...3&d=1739539112
After testing to ensure all worked (including the Dakota Digital tach) I cleaned up the wire runs and wire loomed/taped as appropriate.
I'm now ready to download my Lund tune I received the other day. I'll document that after completion.
Mark
OBD II engine light trigger?
I need help on what causes the OBD II eng light to come on (See pic below). This OBD II and light are from the Ford Performance ECU/PCU package I bought with the Gen 3 Coyote. I'm NOT referring to a engine code occurring that would illuminate the bulb......, but is it a +12v signal to the engine light or a (-) Negative trigger which would mean the bulb has +12v as a constant and needs a ground to cause it to illuminate/turn-on when a code happens.
I know I can put a multimeter on the + and - wires to the bulb to help determine that, but trying this route first.
The reason I'm asking is my Dakota Digital instrument cluster has an engine light warning built into it and needs a (-) negative ground input to cause it to illuminate.
Thx Mark
https://thefactoryfiveforum.com/atta...2&d=1739976378
Tinting Door and back cab glass
I'm winding down on inside work. Today, I decided to tint my door and the cab's back glass. This is a very easy process, especially with the glass on the bench vs installed. If you decide to do yourself, watch a few YouTube videos. Just need a squeezy, distilled water with a few drops of baby shampoo, rubbing alcohol in some spray bottles and a few razor blades for trimming. If you don't want to tackle this project yourself, take the glass (pre-install) to a tinting place and have them do it. It should be a lot cheaper with the glass out vs installed.
Here's the process I used.
1. Cleaned glass with microfiber towel. Last step to clean with rubbing alcohol.
2. Spray glass with soap solution. Then peel clear backing off the tint and spray the glue side with soap solution. NOTE: you can't apply too much.... so make it wet! Pic below
https://thefactoryfiveforum.com/atta...7&d=1740500668
3. Then, starting in the middle, working out to the edges, squeezy the soap solution out from under the tint. Start easy until tint doesn't slide, then pressing harder to get as much water out. I also spray soap solution on the tint exterior to lubricate the squeezy on the tint. See pics below
https://thefactoryfiveforum.com/atta...8&d=1740500756
4. once squeezed, I rough trim the tint and let the tint set a few minute. This pic of rough trim.
https://thefactoryfiveforum.com/atta...9&d=1740500808
5, for the final trim, I used the other door window as a guide. I offset the glass about 1/16" and time the tint leaving the 1/16th" glass that will be under the rubber. Here's 2 pics showing the final process.
https://thefactoryfiveforum.com/atta...1&d=1740500868
https://thefactoryfiveforum.com/atta...3&d=1740502982
Set glass tint side up and let dry at room temp for a few days.
NOTE: for the back glass I did the same process except I trimmed the tint on the solid black window just past where the poke-a-dot pattern ends.
https://thefactoryfiveforum.com/atta...4&d=1740503002
Good luck,
Mark