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Old 08-10-2020, 09:57 AM   #41
AllenV
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Default Crack after straightening the frame

some shots of the crack after the straightening
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File Type: jpg crackafteroutside1.jpg (47.0 KB, 38 views)
File Type: jpg crackaftertop1.jpg (42.0 KB, 37 views)
File Type: jpg crackafterinside1.jpg (46.7 KB, 34 views)
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'55 F100 with slightly newer 292 Y-block
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Old 08-10-2020, 10:03 AM   #42
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Default prepping the crack for welding

Since I have clear access to both sides of the crack and the frame is comprised of 10GA steel I choose a square butt joint weld rather than a V-groove scheme. I opened the gap using a hack saw down the length. Then I built several mock-up cracks and frame sections to set up the welder and verify good penetration and repair of the crack

Here is the crack after clean up
Attached Images
File Type: jpg CrackAfterClean.jpg (34.5 KB, 34 views)
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'55 F100 with slightly newer 292 Y-block
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Old 08-10-2020, 10:07 AM   #43
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Default weld set up

Here is a shot of the mock-up frame including a prototype "crack". I used this to set up the welder and to practice welding in the orientation and location as the real thing. The next shot shows a test coupon I cut in half to verify weld penetration and good gap repair.
Attached Images
File Type: jpg weldTestCut.jpg (34.0 KB, 29 views)
File Type: jpg WeldPenetration.jpg (28.3 KB, 29 views)
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Old 08-10-2020, 10:12 AM   #44
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Default The crack is welded

Eventually I got to where there was nothing left but to weld that darn crack.
After welding I ground it flat where I will attach doublers on the inside and where the cab mount bracket fits on the outside.
Attached Images
File Type: jpg WeldOutside1.jpg (37.5 KB, 36 views)
File Type: jpg WeldInside5.jpg (31.9 KB, 34 views)
File Type: jpg CrackRepairedOutside.jpg (37.9 KB, 34 views)
File Type: jpg crackRepairedInside.jpg (31.3 KB, 31 views)
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'55 F100 with slightly newer 292 Y-block
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Old 08-10-2020, 10:20 AM   #45
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Default Put doublers on

I made two doubler plates of 1/8-inch steel. I used a bowtie configuration of "fish plate" due to the short distance between the crack and the transmission cross brace. The top doubler was also tapered. Before welding I applied "3M weld-thru Coating II" to both faces. One of the images shows the 3M coating before welding. I did the welding in, roughly 1 inch, stitches, letting the frame cool considerably between welds. This was to prevent warping the frame with heat.
In that last picture I have set the new cab bracket in place, just to have a look at it.
Attached Images
File Type: jpg DoublerPlateBefore.jpg (65.9 KB, 31 views)
File Type: jpg ZincCoating.jpg (52.9 KB, 31 views)
File Type: jpg DoublerWelded3.jpg (72.5 KB, 32 views)
File Type: jpg TopDoubler1.jpg (65.7 KB, 31 views)
File Type: jpg TopDoubler4.jpg (47.3 KB, 31 views)
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'55 F100 with slightly newer 292 Y-block
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Old 08-10-2020, 10:38 AM   #46
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Default install new cab brackets

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I had deep penetrating rust at the holes in the cab brackets where the cab mount rubbers sit. Since I had one bracket off anyway, I decided to put on new brackets. These came from LMC. They look really nice except that 4 of frame-bolt holes are misaligned with respect top my frame. The 2 holes at the front-side of the frame were fixed with a bit of filing. The 2 holes on top of the frame were the most offset, and the most critical. These I want to be well aligned and have minimal slop as the torque of the cab weight pulls sideways on these bolts. Naturally, the misalignment was exactly opposite of what I'd like. Meaning that the bracket hole was inboard of the frame hole. I set out to move the holes into the correct location. I filed the hole in the bracket until I could get a bolt inserted. Then I added metal to the other side by welding. A little bit of work with a flat file and a round file then made it good.
Attached Images
File Type: jpg cabBrack_hole1.jpg (31.6 KB, 24 views)
File Type: jpg cabBrack_hole2.jpg (28.2 KB, 25 views)
File Type: jpg cabBrack_holeWeld.jpg (27.3 KB, 24 views)
File Type: jpg cabBrack_holeFinished.jpg (28.1 KB, 26 views)
File Type: jpg cabBrack_install2.jpg (42.8 KB, 24 views)
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Old 08-10-2020, 10:55 AM   #47
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Default Re: '55 F100 new project, new member

Very nice work!
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Old 08-10-2020, 11:49 AM   #48
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Default Re: '55 F100 new project, new member

Quote:
Originally Posted by dmsfrr View Post
Very nice work!
Thank you, It's been fun to "up" my welding game.
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Old 11-06-2020, 11:33 AM   #49
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Default Re: '55 F100 new project, new member

Hey Folks,
I have been remiss in posting my F100 progress here. Time for an update.

First: I have been putting up regular detailed reports on the Ford Truck Enthusiast site. You are welcome to go there to see the minutiae. Here is the link.

https://www.ford-trucks.com/forums/1...project-5.html

Broad strokes:
Finished the frame repairs with cracks located and felt with in 6 places. The frame was sent out for sand blasting and powder coating.

While the frame was gone I set to work on the front axle and hubs as well as the rear axle and springs.

Front Axle: I measured excessive lateral play in the king pins and installed new kingpins that are 0.010" over size. This required some work to bump out the size of the openings in both the axle and spindles. Now the kingpins are a very nice fit. While the hubs were off I noted spalling and damage in the wheel bearings. Both hubs got 4 new wheel bearings. All parts were painted.

Rear Axle: The rear axle is the Dana 44, 19 spline with 3.92 gearing. I have no reason not to believe it is original. I cleaned out the sludge and grunge from the inside. All parts were painted and new axle and pinion seals were installed. The wheel bearings felt okay to my hand so I left them as-is. If they prove to be noisy I'll replace them later.

Rear Springs: I found nothing beyond normal wear on the springs. Took them fully apart and cleaned off the dirt, rust and scale. Reassembled with new center bolts and new bolts on the rebound clips. The eye bushings were replaced with new as were the spring pings and the rear shackle.

Current status: Frame is back and has been mated with the front and rear axle units. Moving on to the brakes.

Some pictures:
Attached Images
File Type: jpeg IMG_1354small.jpeg (203.1 KB, 35 views)
File Type: jpg IMG_1272.jpg (43.0 KB, 35 views)
File Type: jpg IMG_1277.jpg (39.1 KB, 37 views)
File Type: jpg TOE_IN2.jpg (58.8 KB, 35 views)
File Type: jpg IMG_1382.jpg (57.6 KB, 33 views)
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Old 11-06-2020, 07:21 PM   #50
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Default Re: '55 F100 new project, new member

nice job on the frame that will be plenty strong
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Old 12-01-2020, 03:32 PM   #51
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Default Re: '55 F100 new project, new member

You are doing a great job. Reminds me of a 06 Subaru Baja trubo I bought last year. Everything had to be done, I've since named it the money pit. LOL
Keep up the good work.
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Old 12-01-2020, 05:50 PM   #52
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Default Re: '55 F100 new project, new member

I knew things looked familiar! Been following you on FTE. Good work!!
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Old 01-25-2021, 04:38 PM   #53
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Default Re: '55 F100 new project, new member

Hey Folks,
I'll get you updated, I hope, today. But first I have a question for the Y-block experts. I have the motor out and the transmission removed. It would be sweet to change the rear main seal. To my untrained eye this looks like a design that does not allow the seal to be changed with the crankshaft in-place. IS this the case? If the seal can be changed, I'd love to know how.

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Old 01-25-2021, 05:04 PM   #54
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Default Re: '55 F100 new project, new member

Since I put up that post with the lovely black frame sitting its own wheels I have decided to fix a problem that I had been deferring until later. Namely the rear axle had some internal rust damage at the surface where the wheel bearing is supported. A new wheel bearing slid in far too easily and had significant slop. In fact, I measured 0.025" vertical play with the new bearing installed.
I finally faced the music and committed to a solution. A new axle was needed. I failed to find a Dana 44 within any distance I was willing to drive for pick-up. A conversion to a newer Ford 9-inch looked pretty attractive. In fairly short order a local CL ad appeared offering the rear axle from a 1964 Ford F-100. From 1957 on, the F100 shipped with the Ford 9-inch rear as standard. I thought I was going to see an early 9-inch rear in this ad. BUT, what I found was a Dana 44-1. This truck had been optioned with limited slip and at the time Ford used the Dana 44-1 in all limited slip trucks. This axle came home with me.
Since the 44-1 is a slightly larger (2.75") tube size, the 1955 brackets did not fit so I used spring cap plates from a 1957-60 truck with a fabricated 1/8-inch spacer and fabricated my own shock mounts which place the shocks in the same location as the 1955 mount.
I am using the original 1955 brake backing plates and all 1955-spec brake parts. The axle shafts are from the 1955 unit, slightly shortened to accommodate the limited slip differential.
PHOTO 1: Dana 44-1 installed
PHOTO 2: the tags from the Dana 44-1
PHOTO 3: the new shock brackets before paint
PHOTO 4: close-up of the new spring cap and shock configuration
Attached Images
File Type: jpg Dana44d1 installed.jpg (85.6 KB, 14 views)
File Type: jpg Dana44d1 tags.jpg (34.1 KB, 14 views)
File Type: jpg IMG_1469.jpg (33.9 KB, 13 views)
File Type: jpg Dana44d1 new mounts.jpg (47.4 KB, 13 views)
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Old 01-25-2021, 05:08 PM   #55
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Default Re: '55 F100 new project, new member

This takes us to a milestone. The chassis, axles, suspension and brakes are finished.

Recall that the whole reason this truck came apart was to fix frame cracks revealed when I was starting two replace the brakes which had ceased functioning. Since then

Frame cracks have been repaired in 6 places ( I showed you 3 of those)
Cab support frame arms replaced
Frame powder coated
Front leaf springs replaced along with new bushings
Kingpins replaced
Front and rear wheel bearings and seals replaced
Rear spring bushings replaced
Rear axle, complete, replaced with the Dana 44-1 (limited slip)
New brake hardware throughout

When I got it sitting on all 4 tires I was able to measure the droop of the cab support arms
Driver's is 6/32", passenger side is 5/32"
That is within 1/32" matched left to right. Pretty happy with that. The cab ought to be square with only a 1/32" shim on the driver's side.

NEXT UP: On to some clutch and transmission work. A nice change of pace.

Photos:
Attached Images
File Type: jpg IMG_1488.jpg (68.0 KB, 13 views)
File Type: jpg IMG_1489.jpg (72.9 KB, 13 views)
File Type: jpg IMG_1490.jpg (81.7 KB, 13 views)
File Type: jpg IMG_1491.jpg (55.9 KB, 13 views)
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Old 07-15-2022, 03:42 PM   #56
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Default Re: '55 F100 new project, new member

I has been a long time since I last posted to Ford Barn on this project. A few thing have happened since the chassis was completed. I also took a nine month vacation from the project.

But first, I have been keeping a detailed thread over at FTE. I now have a link to that in my signature below.

After the chassis, I cleaned up and inspected the transmission. This is the T-98 “synchro silent”. It had the common “very loose” shifting. I found the usual worn pin and hole at the fulcrum of the shift lever. A new pin and shift lever fixed that.

I was going to then reattach the transmission to the motor and pop the unit back into the chassis. After all, the old 292 Y-Block was running quite well. But, the rear main seal needed replacing, so the oil pan came off. Then experienced folks counseled removing a main and rod bearing cap for inspection. That turned out to be a wise move. Some of the bearings were badly spalled. The motor needed a full rebuild.

Thus the projected tacked into a motor rebuild phase. I tore it down and delivered the block, heads, crank, pistons-and-rods, to a machine shop. He marveled at the extreme wear of the valve seats and we estimated it would need 0.030” over 312 pistons. The block was deemed a good candidate for boring using sonic testing of the cylinder walls. The heads I had were mismatched so we swapped them for a matched set he had in-stock. Eventually all the work was done. Cylinders bored for new pistons. Block line bored and all the oil passages cleared out. Cam bearings replaced. The rod big ends were honed back to round and new inserted installed in the small end. The heads were decked and reworked with new valve seats. New valves installed.

When I got it back I painted it red and am now doing the reassembly.

A few images:
The first 4 are the old tired motor. The last three are the motor back from the shop and then painted.
Attached Images
File Type: jpg IMG_1590 reduced.jpg (28.3 KB, 20 views)
File Type: jpg IMG_1583 reduced.jpg (94.5 KB, 21 views)
File Type: jpg IMG_1582 reduced.jpg (68.8 KB, 21 views)
File Type: jpg IMG_1591 reduced.jpg (92.3 KB, 21 views)
File Type: jpeg motor unwrapped.jpeg (162.3 KB, 21 views)
File Type: jpg IMG_1752 reduced.jpg (50.5 KB, 22 views)
File Type: jpg IMG_1753 reduced.jpg (56.5 KB, 21 views)
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Old 03-06-2023, 05:57 PM   #57
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Default Re: '55 F100 new project, new member

Hey Folks,
I have been “off task” on my F100 restoration for a number of months. But now I am back to it. As you can see in the images, the rotating assembly is built and the heads are on.
To remind you, this is a 292 with a stock cam. The pistons are 0.030 over for a 312 but the crank and rods are original 292.

Now, as I turn my attention to the rocker arms, I have found badly worn rocker arms as well as the threaded adjuster that rests on the end of the push rods. (See images)

So, I need rocker arms and adjusters.

I already have a pair of new rocker arm shafts from Mummert, along with Mummert’s kit of springs and washers. And a complete set of “stock” push rods. The push rods are Mummert’s PR-1221-HP, LONG Pushrod for 54-55 and 60-64 heads.

Where should I look for rocker arms and adjusters?? This is a stock build. I just measured the rocker ratio at 1.37-ish. They all appear to be the same. That said, I have no reason to believe that the rockers I found in the motor are correct.

If it matters, the block is an EDB-E casting and the heads are ECL-C

Images:
Attached Images
File Type: jpg IMG_0861.jpg (61.9 KB, 11 views)
File Type: jpg IMG_0862.jpg (66.7 KB, 10 views)
File Type: jpg IMG_0864.jpg (57.0 KB, 9 views)
File Type: jpg IMG_0873.jpg (35.1 KB, 10 views)
File Type: jpg IMG_0875.jpg (33.1 KB, 9 views)
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'55 F100 with slightly newer 292 Y-block
find the detailed project story at
https://www.ford-trucks.com/forums/1...o-project.html
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Old 03-06-2023, 06:49 PM   #58
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Default Re: '55 F100 new project, new member

Well, I went hunting for rocker arms and found what are supposed to be very nice remanufactured assemblies on e-bay. New Elgin shafts. EAN6564 or 5751066 1.43 ratio rocker arms. And posts in good condition. Rocker "tips surfaced as needed"
My rockers are 5751066. So these seemed a good match. I bought these assemblies as well as a set of 16 adjusters.
We'll see what shows up.
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Old 03-07-2023, 09:05 AM   #59
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Default Re: '55 F100 new project, new member

Sounds like that truck you bought for what was most likely a "reasonable amount" is getting "more reasonable " by the day. We all been thete.��
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Old 03-07-2023, 09:39 AM   #60
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Question Re: '55 F100 new project, new member

Quote:
I went hunting for rocker arms and found what are supposed to be very nice remanufactured assemblies on e-bay ...
Can you give the source of the supplier?
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