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  #301  
Old 05-08-2020, 06:56 PM
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Crankyolman Crankyolman is offline
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Today was a nice dry sunny day so I pushed the bed outside and set about priming and undercoating the bottom side. That went real well



It's now fully protected on the bottom side. While I had it upside down it was easier to take care of the rockers so I sanded those down so that part will be ready to prime when the time comes. It's now safely back in the garage where as soon as it's fully dry I will once again flip it back over, than push it back outside tomorrow and hopefully finish sanding it down and get the primer on it.
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  #302  
Old 05-10-2020, 12:26 AM
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I'm moving right along on this little project.



Today was sunny and bordering on hot. I managed to get the bed flipped upright and back on the cart without too many problems. Then I rolled it outside along with my air compressor and split my time between working on the bed and cleaning and mowing the back yard. I managed to get the left side stripped





then moved on to the front. The front of the bed is fairly beat up particularly along the bottom like many of these beds tend to get.

In the picture you can tell the high spots which have no paint Vs the low spots which do.


I was alternating between beating the dents back out and sanding when my wife came out and told me it was getting too late to work and the neighbors would like a little piece and quiet so I quit for the day. I don't really expect to get this part completely perfect but it is already looking much better that it did.


For the record the neighbors have been very supportive of my efforts, even the mail man stopped to talk to me about it today



Plans for tomorrow are to get more of the yard done and finish stripping and prepping the bed and hopefully get some primer on it. While stripping the side I found a few high and low spots that had to be addressed, nothing big but one small holdup there is my quarter sheet palm sander, that I have been using to sand bondo, broke so the bondo sanding is all being done by hand and Harbor freight sandpaper sucks and my right shoulder has a couple of bones with no cartilage between them so sanding is taking a little while because if I do too much of that particular movement it becomes very painful.
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  #303  
Old 05-10-2020, 11:41 PM
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Crankyolman Crankyolman is offline
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I finally finished stripping the bed today I only ran into one little issue. While stripping I noticed the welded joint at the forward corner of the bed was badly cracked.






Then I checked the other side and found the same thing only not quite as bad



So I grabbed the welder and made a quick repair bead and the bed is now ready for primer. I had planned on priming today but something came up and I ran out of time so hopefully I can get that done tomorrow morning before any rain moves in.


I also managed to get a third of the back yard done. It's not easy mowing down waist high grass and weeds with a cordless weed wacker but it's coming along.
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  #304  
Old 05-11-2020, 03:53 PM
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Crankyolman Crankyolman is offline
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I got up this morning at the crack of 8(ish) eager to get the bed primed before the rain came this afternoon. While wiping down the bed I found another minor dent I had missed and had to fix that real quick. Then I set to work priming. The guy I borrowed the paint gun from couldn't find the lid and said he never uses it. I'm not a big fan of that so I ordered a coupe lids off Amazon but they haven't yet been delivered. So I decided to try to do it his way and use it open top.


I'm sure you have an idea where this is going


Things were going OK until I painted the inside of the bed rail, then as I raised the gun above the rail to get it out of the bed I also raised it above my head... That's when I felt the cold splash of epoxy primer on top of my head, face, arm and chest I had to close my left eye to keep it out and used up what was left in the gun then grabbed the can of acetone I had sitting there for clean up and ran inside. Basically I took an acetone shower and surprisingly managed to get most of it out of my hair, face and beard.



I then went back to work and while looking for something else found some gloves I had gotten for painting and came up with the idea of using one of those as a lid which actually worked






I then managed to get the rest shot without incident.









So the bed is now just a little wet sanding away from being ready to paint


I don't like this paint gun, it makes me really miss my old Binks 62.
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  #305  
Old 05-21-2020, 10:41 AM
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I can't believe it's been 10 days since I have updated this thread but I've been very busy and had to go back to a regular work week last week.

I'm still sanding on the bed but I got the fenders painted and began wet sanding them. Priming the fenders went a lot better than the bed and I got the gun to lay the primer on fairly smooth so they won't need that much sanding work.

The weather is being a bit unpredictable, even for the weather people, they can't seem to get anything right which makes planning a problem but I'm pressing on with whatever I can.

Of course my habit of doing goofy things is kind of slowing me down. Ever since I began working on the header panel it's been bothering me that the lower panel has dirt, rocks, debris and rust in it so I decided I better remove it, de-rust it and see exactly what needs done rather than just treat and coat it like I was considering. After all I've done so much to the truck at this point and never want to do it again so I may as well do it right regardless of the amount of time it takes.

Well, the original header panel is being a pain to remove. The bolts were very rusty and at risk of breaking so I have been soaking them in penetrating oil for a week now in preparation for removing. That actually went well except I'm having trouble reaching the one behind the steering gearbox. I think I just need to bring home a longer wrench from work and I'll be able to get it. In truth I should pull the steering gearbox and take it down to Redhead and have them rebuild it while the truck is down because it's leaking but my annual budget for the truck is so far back in the rear view mirror I can't even see it any more. So that is going to have to wait.

In the mean time I started looking at the '69 header panel I had sitting around that I was thinking about using as a wall hanging. A while back I was considering swapping them but changed my mind. At that time SOLSAKS and I discussed me sending him the header but I talked him out of it because it has rust problems and I felt it wasn't worth even the cost of the shipping it would take to sent it to him.

Anyway, I'm working on getting the original header off, sanding on various parts and start thinking that maybe that header is salvageable after all. I really shouldn't be allowed to think some times . So I start looking at the header, remove it from the core support and Yep It's pretty bad. There is rust between the top and bottom panels that are spot welded together







and a lot of holes in the bottom panel










but I've gained a lot of knowledge about rust removal and rebuilding this stuff in the past couple years so decided I might just tackle it.


So first thing, I did was take it to work to make sure there weren't any other major problems. The first problem was pretty minor. It seems that in '69 the radiator was mounted about 2 inches further back than on the '72






That was easy enough to fix by making the cutout match the '72 cutout


Then I proceeded to strip the paint off. There was a fairly minor dent I had to beat out but that was it as far as the top section



There was only a small dent that needed taken out so it seemed like I was good to go on the next step, the acid bath.
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  #306  
Old 05-21-2020, 11:19 AM
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So I made up a "tub" out of 4x4s and plastic, set the header in it, boiled 15 gallons of water, added 15 cups of citric acid and poured it in the tub.



Then wrapped it up to keep the heat in



and let it sit for 24hrs then took it out and pressure washed it.


This removed all the rust and revealed just how bad the rust had been












At this point it should have just become a wall hanging again but only slightly daunted I decided to press on and took it in to work so I could work on it in my free time.


Now the real work began. I brought in the inner fenders that I had removed from the bed to use as repair panels and set to work figuring out just how to deal with this.


I didn't want to remove so much metal at one time that things would shift so I began with the center section. I figured out the patch panel first



Then cut out the bad metal that it would be replacing



Underneath it was nice and solid



So I then tacked the repair panel into place



Next was the section to the right of that which included some angles and went all the way to the end of the panel



I fabbed a new patch leaving the stiffening ridges out because I think this metal is so thick it really isn't necessary and I tacked that in place



Then a little patch where the 2 panels meet that was a fairly complicated shape



Then on to the right side I cut out the rest of the center section that needed replaced and a 6 inch square section to the far left



Fabbed up the patches for those



and tacked them in place



That finished all the tacks


Then I set to work with the TIG doing the full welds on all the patches. The TIG takes a lot longer than the MIG but gives a nicer weld and I still don't have the MIG working right. I got about 3/4s of that done before I ran out of time so I will have to finish that up Friday or Saturday. I also need to fabricate and add some drains which should also happen this week.
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  #307  
Old 05-23-2020, 09:59 AM
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Yesterday I managed to finish welding up the header panel.



Then I made up some drain covers



Made some drain holes and welded the covers on



Now all that's left is to remove the bit of flash rusting and whatever wasn't fully submerged in the acid bath and it will be ready for priming and painting.


I also brought home my longest 1/2" wrench so hopefully I can get that last bolt out of the original header and see if I want to give that one an acid bath as well and fix whatever problems that reveals.
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  #308  
Old 05-24-2020, 01:15 PM
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Yesterday I got the original header off and soaking in an acid bath. I checked it a little while ago. Most of the rust is gone but there was still enough that it needed a longer soak so I put it back in, wrapped it up and will let it go another day.



The '69 header is complete, cleaned up and ready for primer and paint.



Today's plans are to wet sand one of the fenders and that's about it.
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  #309  
Old 05-25-2020, 11:06 PM
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Great progress!
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  #310  
Old 05-26-2020, 09:56 AM
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Crankyolman Crankyolman is offline
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Quote:
Originally Posted by ddversatile
Great progress!


Thank you. It's going slower than I had hoped but I try to do something every day so eventually I will get it finished.
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  #311  
Old 05-26-2020, 10:20 AM
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So, here is yesterday's progress.


I took the '72 header out of the acid and power washed it and blew it dry with compressed air. I have to say the original under coat did a hell of a job protecting it over the years. Most of it is still there and in good shape even after the acid bath.



The only big problem was the lower left corner.






Given everything I did to the other one this one was a piece of cake. First step was to make a paper template, then fab a new corner piece, then cut out the damage and trim the new piece to fit



Then weld it in place




I found a few more minor issues with some other areas that just needed some welding to fix and that was it. Now I need to strip off the old paint and grind down a few welds and it will be ready for treating and priming.



As it looks right now the original header will be the best of the two. What I'm considering is painting both of them, using the '72 and hanging the '69 on a wall along with the spare tailgate in case something ever happens and I need to swap them out in the future. Perhaps that's just the hoarder in me but it never hurts to be prepared.
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  #312  
Old Today, 10:36 AM
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Crankyolman Crankyolman is offline
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I made a little more progress yesterday. I got the front of the '72 header stripped.



I found a few more minor things that needed welded, one area needed a small patch made up and welded in.



Hopefully tonight I will get the back side and bottom prepped so any body filler that is needed can get done and I can get everything in primer.
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