'68 F250 Flareside 2wd Restoration

[Tomcat45]

Thought I would start a thread to post my progress, ask questions, and to get motivation when motivation runs low.

Here are some before pictures.

Those mirrors will have to go.

That antenna just don't get it either.

Those steps under the doors were the first thing's to go.

That rear bumper is history.

To bad the seat has that big tear in it.


That metal box on the inner fender is gone.
This was a farm truck. reciepts in the glove box show about 66,500 miles on it in 1996. the odometer reads about 70,000.
There is documentation of 3 different owners from the original owner in 68, another owner from 96 to 2004, then another from 2005 to 2006,
and there were 2 more that owned it from 06 to when I bought it in 2010.
I think the milage is accurate. The interior doesn't show to much wear and tear in the normal areas,
Floor mat, clutch and break pedals, other than the split in the seat the rest of it look's new.
No big deal I guess. When I get it done it will be like new or better.
I have more to post, just not tonight. Should be in bed by now. Morning gets here to early. 1:30 A.M.

[jzjames]

Congrats on the new Stepside - with a nice inline six to boot.

[Tomcat45]

After removing the bumper I decided I need a ner radiator support.

The stone guard is rusted through middle brackets. I haven't got any pic's of it.

Right now I'm repairing the holes in the bumper and getting ready to paint it.

Sombody I work with gave me this support out of a '78. It has some rust where the battery sets. and some minor
modifications for the "68 grill.

[Tomcat45]

A Truck With No Face!

I could have fixed the hole, but the rust at the bottom is behond my fab skills and tool inventory.
I have no idea what the hole was for. There is a hole in the fire wall that's inline with this hole. At least they used a hole saw on the fore wall.

Here's a pic of the bumper after welding up some holes.

[Tomcat45]

1978 to 1968 Radiator Support Swap

The first thing I did was bolt the ’68 grill to the ’78 support using the hole for the safety latch, the hole at the bottom in the center of the radiator opening, and one at each end at the top.

Safety latch


One at the bottom in the center of the radiator opening.


One on each end at the top.


The socket’s for the turn signals wouldn’t let the lower brackets set all the way down.
The reliefs in the ’68 was stamped in closer to the bottom edge of the support.



The lower brackets set up about 3/8 of an inch.


I drew some lines where I wanted to cut. I only cut the 2 lines with the arrows pointing at them. The arrows are also pointing at the corners in the relief. Make sure you cut past this point. There is a rib on the other side, I didn’t quite cut to it. Then I cut the 2 lines.
Then I used a block of brass to support the back, and tapped down the cut area.







Notice small rib.


Now there is plenty of clearance for the light socket.



The bracket still didn’t set all the way down. There was a nut that had to be removed on both sides. Don’t worry that nut wasn’t needed on the ‘68



Now everything sets good. Next I drilled the holes for the lower brackets and for the hood latch.

The radiator opening on the .68 was 24.5” wide, the “78 was about 22.375”. I had to cut about 2.125” out and drill 2 new mounting holes.

While I’m at it this will be removed and the associated flare on the top of the support will be cut out and a new flat piece welded in to look like the ’68.



Right now I’m welding things up and repairing a rust area. Then I’ll sand blast and do some bodywork on the highly visible areas above the grill.

[Tomcat45]

Found 2 more weld nuts that have to be moved. One of the inner fender nuts on each side has to be moved. Will post pics when I start the modification.

If you look at pic #7, the one with the hammer in it. The nut on the left needs to be moved.

[jzjames]

Fabricating skills.....priceless!

[papabug71]

Keep up the good work ! !

[Tomcat45]

Thanks

I'm going to do a compression check on it today, before I pull the old radiator support out.
Pulled both fenders this week. They'er rusted through behind the renforcement rib that attaches to the cab near the bottom.
Not sure how I'm going to fix them. Fiber glass or Weld. I will decide after I sandblast them.

[72stepside]

Ahhhh, an 8ft stepper F-250 with an inline 6. You lucky devil !!!! There are NONE of those around here.

[Tomcat45]

You don't see them around here either.

[Tomcat45]

Bought some fenders the other day. they were supposed to be bondo free. the drivers side is in good shape except for a small dent in the bump back near the cab, and some heavy surface rust under the hood. Starting to rust through at the bottom near the cab. Now I have 4 fenders rusted in the same spot. the other fender had quite a bit of bondo in it. I'm glad the bondo was free cause I sure would hate to pay for it.

I cut a small opening in the support brace where the rust area is. How much of this can I cut/or should I cut to keep moisture and dirt from accumulating?

If you look close you can see some of that free bondo growing in the dirt

[72stepside]

They all rust there. I think I'm gonna cut a 'slit' in the bottom so that it can drain, then coat with POR-15.

[Tomcat45]

I haven't given up or gone away. I've been building a workshop. Will post more when the shop is done.