After fixing the grill gaps I moved to the passenger side cowl. The bottom edge had rust in it that I had already cut out. I pulled string to determine where to fold the bottom edge to match the body line in the door. https://i.imgur.com/loP3eA8h.jpg https://i.imgur.com/ngfuJPHh.jpg The aluminum c-c...

Same process on the other side. https://i.imgur.com/ojl0kw3h.jpg https://i.imgur.com/Cuq5zIMh.jpg https://i.imgur.com/ypUCJRPh.jpg https://i.imgur.com/T8qmFBph.jpg https://i.imgur.com/G54Zb0Bh.jpg The grill opening didn't match the grill edge on either side, so I welded 1/8" rod to close up the...

Getting the doors and hood in alignment meant I could work on making the bottom of the hood fall in line with the body line that goes through door. I used string to pull a reference line to see where to trim the hood. https://i.imgur.com/L0NUNpgh.jpg With the string set, I clamped a straight edge in...

You do fine work, all the gear heads that see it will appreciate that kind of workmanship. Thanks Grump! Unbelievable workmanship and level of detail. No truck ever came out of ford plant with that level of panel fitment and gap fitting. Your work is in a class by itself. Thanks! I agree, this is m...

Driver side door progress. The rear edge of the door from the window frame down didn't fit too badly after the initial adjustment but the window frame was sticking way out. https://i.imgur.com/lK8apv5h.jpg https://i.imgur.com/eLIWfz5h.jpg https://i.imgur.com/LCSCNiNh.jpg Cowl top had the same mismat...

Continuing on the passenger door, the gap against the rear jamb was too big. The mismatch in body lines is intentional- the overall panel shape fit best with the door aligned here. I can use a hammer and dolly to move the short cab corner body line upward to match the door's crease more easily than ...

Beautiful craftsmanship as always. It's really going to be a shame to cover all that up with paint!! Thanks! It would be pretty cool to leave it bare with clearcoat to protect it! I've recently thought about scaling back to just specialize in panel gaps and panel fit; a gapped/fitted bare metal tru...

The drip rail had a high spot up front so I tapped that down with a hammer and delrin block. https://i.imgur.com/6QI5Jydh.jpg Gap along the middle was pretty good. https://i.imgur.com/4Tt0EPuh.jpg This angle doesn't show it well, but there was a slight high spot in the curve at the rear of the drip ...

The door was way off before I took the truck apart, and stripping the paint didn't magically make them fit better. https://i.imgur.com/MFBOfRvh.jpg https://i.imgur.com/RleNFMVh.jpg https://i.imgur.com/00pwdp9h.jpg https://i.imgur.com/u0QB11Qh.jpg https://i.imgur.com/AnWlxKbh.jpg The door was sunk in...

Getting back to panel alignment. I started by measuring the frame height at the ends and body mounting points to make sure it was level and not twisted. It was off a bit so I checked tire pressure and found that the right front was down to 12 psi which was causing that corner to sag. With all tires ...

that looks better than what ford made and im sure functions better.i hate to think of the man hours involved in the hinges but looks like its worth it. I have around 25 hours in rebuilding a pair, not including painting them. The hood opens smoothly now and can easily be lifted with one finger. It ...

WOW! That's really going above and beyond. I haven't bought any repop hinges but have heard/seen stories of them being bad. (trying to use nice language :) ) I've tried to pick up as many original sets as I can find for future use and or repairs. Thank you for all of the details during your rebuild...

The finished hinges. https://i.imgur.com/8WKLYxSh.jpg https://i.imgur.com/x2Imd2Wh.jpg https://i.imgur.com/DFPD3hVh.jpg https://i.imgur.com/VVGvAbph.jpg https://i.imgur.com/8KYPwxTh.jpg https://i.imgur.com/46JLmlbh.jpg https://i.imgur.com/M6Xo7MBh.jpg https://i.imgur.com/vs4hWfzh.jpg https://i.imgur...

The finished pins, along with billet countersunk washers from All American Billet. https://i.imgur.com/8FkwLN0h.jpg https://i.imgur.com/HfjExeCh.jpg https://i.imgur.com/dV6QZhih.jpg https://i.imgur.com/8DSsewJh.jpg This is where a lot of time was spent getting the joints dialed in. The pins were mac...

The arms were out of alignment, none of the pivot points were parallel from one end to the other. Some had high and low spots along the friction surfaces. https://i.imgur.com/Bo996bch.jpg https://i.imgur.com/zdVVBZLh.jpg https://i.imgur.com/47DD3wHh.jpg https://i.imgur.com/KcorrFoh.jpg After straigh...

After searching the Ford truck forum for hood hinge info it seemed like the hinge rebuilding companies that others had used in the past were no longer willing to rebuild this style of F100 hinges, I think due to the hinge pin's rectangle shaped end that is used to rivet the pin in place. So, armed w...

Long winded update hood hinge, I'll break it up into a few posts. The reproduction hinges ended up not working out once the hood was bolted on. Long list of problems with them- 1: The joints were too tight. I had to use a 24" adjustable wrench slipped over the flange that bolts to the hood to g...

I hope the owner is going to drive this truck, it would be a shame to have a truck this nice and nobody gets to see it. Keep up the great work. Thanks Grump, I'm sure it'll see plenty of use and car shows once it's finished. I'm late to this post so pardon me if I am rehashing someone else's commen...

With the firewall finished, I moved on to assembling the panels to start correcting panel fit and gaps. I mounted the cab back on the frame along with the front clip after blasting the header panel and doing a bit of initial straightening on the inner fenders. The fenders and radiator support are af...

I did a quick/light blocking with 220 on the areas that were already pretty good, and 180/220 on a few spots that needed a little more flattening. 3-4 spots needed a small amount of filler, and it was ready for the last coats of epoxy to seal it and make it ready for wetsanding and paint. https://i....