First off I am NOT finished, this is just an "in progress" topic
I'll be going into a lot of different things and probably getting into too much detail, so feel free to jump around. I'm mainly writing this out in case someone else goes to do it at a later date so they won't have to search through so much information.
It's important to note a few things here:
1) The truck is going to have 4x4 axles in the future, this will raise the front end. This effected my choice on how to shorten the wheel base quite a bit.
2) My frame has a flat top, no kickup.
3) There is an extensive amount of custom work that needs to follow here. From widening, lengthening and making the fenders taller, to custom bed mounts, custom running boards, ect. This is all custom, it's not something you can buy fitting parts for.
Where she's at as of today (4-6-10)
Bed info:
From 1953-1972 the beds are the same with the exception of the mounting holes on the fenders being a little higher after 56. The LONG beds from 53-72 are TALLER and WIDER, not just longer. From 1973-1979 the short beds where taller and wider, they are basicly a chopped long bed. From 76-79 they have a flat top.
I wanted the long bed's height and width, but not the stretched look. So the 73-79 beds became ideal. I searched for a bed for over half a year and finally got a decent deal on this 1978 bed. I will be angling the top later on, that easy for me. I'm a blacksmith I have the tools and the love for working with metal.
My truck had a wheel base of 154". Though this is great for when you're moving 20,000#s, it sorta sucks when you want a daily driver without a flat bed on it. I love the old step-side beds with a passion, I felt my truck had lost far too much style not having one. Before I even found this truck I wanted to build a 4x4, I got a great deal on this 600 and found it to have a lot of benefits for making a 4x4 truck. For one the front fenders have a larger opening and are wider (the truck is 80" wide in the front, an f-100 is 75.68"). The frame is also thicker and larger so I won't have to swap it out. The large wheels it has on now also lets me know where everything will go when I have my 4x4 wheels, so I can do metal work in the mean time.
However since these trucks have a drop axle in front to put in a straight axle causes the front to lift, to counter this you have to raise the back. The frame on my F-600 was sloped, by moving the axles forward rather than cutting the frame it caused the rear to raise up a few inches, this will help me out later (and to be truthful my current welder is getting a little tired and I think I would always have that wonder in the back of my head of weather or not the welds penetrated enough.)
It's more than likely that I will have a lot of custom work to get my truck to have the stance I want. I love large tires, but I don't like a lifted ride.
This old pic shows the frame, notice there is no kickup, the top is flat.
So I got my bed in:
It actually fit rather perfect, in truth cutting the frame would have made things A LOT easier on this build, but I was taking out about 44" and that is too much to do properly without going under the cab. The brackets can only be so close the weld and I would have had to have gone right through them:
The wheels fill the wheel well nicely, though I want the fenders a little wider (only about 1" each, right now the bed is 78" wide. If I was keeping the duallys I would add 4") but they may need a little extra in the middle for clearance and they do have to be lengthened a little, if nothing else to reach the running boards. The F-600s have lower running boards than F-100s, and it's still a climb up.
The first thing I did was take measurements of where everything was at, and took a picture of it all. This way there is no confusement later on:
I then removed all the rivets I could, leaving the ones on the bottom, I had done this prior to getting the bed while waiting. I used a large angle grinder, made a "cross" all the way through them and chiseled the heads off. I then made a tool that I could pound the rivets through with. For the most part it was fairly easy, though the ones on the spring stops I'm pretty sure where done by a rather evil person as 4 of them took me an hour, but I'll get to that.
The back was then lifted up and supported.
You'll notice the suspension was "loose", just keep in mind it means when you remove that last rivet it's going to "pop" down:
The driveshaft was unbolted and taped (lots of hammering and whatnot, best if the caps don't fall off those.)
After I pushed the axle forward a little, I placed the driveshaft on top of the axle so it didn't get pinned. The driveshafts (I have 2 connected) are to be done later, I just needed the axles moved in one day because I can't leave it where it's at too long:
Knew I forgot something; the break lines. Thankfully they had a disconnecting spot in a convenient place:
The wires go to the 2-speed differential. They where long enough I didn't have to undo them and reattach. Remember I'm planning on swapping axles after I move (moving a truck with a wheel base of 110" or so is A LOT easier and cheaper than one with 154", 154" is too long for almost everything. Plus I wanted my bed and to get to work, lol)
I had to prop the bed up to get the wheels to make it past the fenders. I didn't want to take it apart because I needed the fenders to be sure where to put the axle:
The bed was fairly easy to move on the truck myself, though they are heavy if you're moving it on or off. Like almost all my projects, it would be a lot easier to have a helper or two, I'm just use to doing it by myself cause no one else is as crazy or motivated as I am, lol.
After I had moved the axles forward a little I found I needed to raise the frame a bit more because the brackets where as far as they could go. So I made sure the brackets hadn't turned upside down and jacked up the axle which pushed up the frame, then I moved my support up further and added some spacers. Much better:
The original holes in the back were not large enough for my frame, though the bottom supports still sat square on my frame, it seems somewhere alone the lines on the '78 the frame or brackets moved:
I'll be going back later, but for now I just cut it to where I needed it and made sure it was sitting on the bracket inside not the cover:
I will have to make some custom brackets underneath as the ones on it where made for a frame with a kick up, meaning the two in the middle don't touch the frame currently.
After that I lined the bed up, spacing it 1" from the cab. It was a little dented in a few areas, so lots of checking and paying attention to the dents.
Once the bed was where I wanted it I moved the axles into position. I measured the from the fender to the wheel to center it, which proved interesting cause I actually have 2 different sizes on my rear wheels. (there are actually 3 sets of tires, and on the rear they're miss-matched, but better that then one side with 2 horrible tires, lol)
And then I came across my stupidest problem, the spring stops.
Right in the way. These where evil to remove. I had tried to remove them earlier, cutting them from the back and trying to pop them out. These 4 little rivets would not budge with both heads removed and everything flush. In the end I had to drill them out and beat the spring stop back and forth.
I also had to remove the bottom rivets to the differential connector support as the bracket went right over it and I wouldn't be able to get to it later. I had already moved all the ones on top before putting the bed on.
Then came a lot of measuring and back and forth checking. I worked off a spot on the front axle, but also checked other places. Keep in mind that even if they drilled every hole perfectly in the same spot on either side, that the rivets have a forged down head and there by can be off center or fatter, ect, so you don't want to measure off of that, at least without checking to be sure the edge of it is exactly the same from like the front axle on either side.
I got everything within 1/16" and then I jacked up the rear axle again to make the brackets snug. Then I checked everything again.
Once it was all good, I drilled. I used a 7/16" bit, it's a little larger than the rivets where, but starting with it I was able to make the hole dead center. I tried to "step it" but I found it kept wanting to pull the hole off to one side or another. It's slower but by keeping with just the one bit I was able to make a nice hole:
Be sure to use A LOT of cutting fluid. It makes it go easier if nothing else.
Once there I cleaned up the hole to make sure no metal shards where going to touch the bolts. Then I used 7/16" bolts and washers. GRADE 8.
I tightened the nut, not the bolt, after putting on some red lock-nut to 95lbs.
I only currently have a couple bolts in, at this point I had been working 7 hours and the sun had gone away. Today it's rain/snowing.
I post more on this, including tools and when I do the driveshaft, ect.
This is how she sits now and where I have to work (but I'm grateful for a place to do it!):
And this is my never ending audience. Least I got over my "I can't work when you watch me" thing:
There is still A LOT of custom work to do, but this was a big step on getting there.
Like I said, A LOT of custom work left to do, but I'm glad to finally have a bed, ha. This wasn't the ideal way of doing it, from where it had to be done or whatever, but it needed to be done and it's what I had. Lots left to do, lots to come. Any questions feel free to ask, I may not know the answer but I'm good at pretending like I do, lol.
edit: Today I'll be checking the driveshaft and getting to bolting things down more. Still lots and lots to do, I'll probably paint it (its just a cheap paint job at the moment) so the bed isn't white with green pinstrips before the week is out, even though I'll still have to work on the fenders, ect.