“How-To” Project- Making A Crew Cab/Extended Cab Truck


 -“How-To” Project-

Making A Crew Cab/Extended Cab Truck

Author:         Gunisonbrook

Vehicles Needed:     MB 56 Ford Pickup – Qty 2

Special Tools:     Jewelers Saw/Hobby Saw, Masking Tape

Materials:       Body Filler, JW Weld or Adhesive

Rating:       Novice

#1 The sample trucks are two MB ’56 Ford Pickups and are used for project display purposes only. This process can really be adapted to ANY pickup style vehicles and even cars as the technique is the same for both.


#2 The rivets are drilled and, as in the first picture, the wheels/axles are removed.


#3 Don’t drill out the rear rivet completely on either unit as it will go through the inside of the box.


#4 Draw a line from door jam to door jam on the first piece and window line to window line on the second.


#5 Tape trucks along these lines with masking tape. This helps to work as a guide and keeps the cutting disc in line.


#6 Using the cutting disc begin following the cutting line taking a deep cut with each pass – this does take a few passes to complete. WARNING – these cutting discs are dangerous and have been known to fly from the cutting tool and even from the body – USE APPROPRIATE SAFETY EQUIPMENT. Fiberglass disc tends to be the best as they are tougher – make sure whatever disc you are using is rated to cut metal.


#7 The cut piece should look like this. Using the front of cab from the Door Jam to Door Jam unit and the back of the cab and the box from the window to window piece – set other pieces aside for future projects.


#8 Check your fit – additional grinding/sanding maybe necessary to “true-up” the fit. However if your tape was straight it should be minimal. When fit – remove tape.


#9 Grind out roof tabs inside of each unit.


#10 Place the cut pieces on each chassis.


#11 Using your cutting tool, cut each piece at the same point the body was cut.


#12 Completed cut – front.

#13 Completed cut – rear.


#14 Check fit.


#15 While the cabs are in the stripper – lightly sand the chassis to remove and fringe and smooth the seam.


#16 When aligned correctly, tape the bottom of the pieces TIGHT with masking tape. Tape must be firm to avoid slipping when glued. Only tape the bottom as you will see in the next steps.


#17 Set flat and check for alignment after taping and level. You may need to re-tape a couple times for a perfect fit.


#18 Bend the two pieces back as pictured and place a small dab of adhesive on each of the pieces. Bend back so the pieces adhere to each other, lay flat and check for alignment again. Allow to dry.


#19 JB Weld is used on this project.


#20 Additional adhesive may be added after drying to fill chassis seam gaps and strengthen the seam.


#21 The bodies are also “buttered ” with adhesive and attached to each other. These can be placed on dried frame for alignment purposes. Allow to dry.


#22 After drying prep body with filler and sand. Door lines may be adjusted and or filled as one desires. Sand and primer when smooth. The piece is then ready for final painting. Interiors can then be cut as can glass. Wheels of choice can also be added and glued in place.


#23 When wheels and paint are dry, final assembly can be made. Chassis should rest on chassis fairly smoothly so only a small amount of adhesive is necessary. VIOLA – your crew cab pickup is complete!!


Good Luck and let us see your pictures when done. Send to mini-motors@comcast.net

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