Straightening out the roof was the first order of business on the cab. Sorry I didn't take any before pictures but it had all the typical dents.
Then it was on to repairing the doors. The drivers door was by far the worst. The outer skin on it needed a lot of straightening. Hinges were bent. The passenger door was much straighter but still had some thin spots that required patching.
Cab corners and back panel were good. Just needed to fix a little bit on the front lower panels on the cab.
With the cab metalwork complete (at least for now), it was time to get the perimeter frame up on the table and start work on the chassis. I decided to set the truck up with 2 degrees of rake and 5 inches of ground clearance.
mikie likes it ! great Sheetmetal work, love the sectioned frame rails to give the truck the channeled look keeping a full floor. .. GO spit GO !
The rear axle was the first order of business. Locating it was just a matter of pulling a few measurements from the front horns.
Thanks Sloppy J. I can't take any of the credit for the awesome metalwork. I have the guys at QRSR helping me.
Normally the front end would be next but because I want to run a suicide front end we decided to get the cab into position first, see what everything looked like, and then position the grill and axle. Channeling the cab was the first step and we decided to remove the firewall, section it, and mount it to the frame. It turned out that 2" could be removed from the area above the original forward cab mounts. The other 4 inches had to be sectioned out of the middle of the firewall.
With the firewall roughly in place the floor was cut out of the cab following the shape of the frame rails and mounted to the chassis.
If a guy is going to channel the body, model A bumper bracket to body "spacers" work great when separated as front body to frame mounts...
Channeling the cab created its share of details to be addressed. Starting with rear panel. The panel was first notched to get the cab on the chassis, then the lower bead detail had to be moved up 2" to meet the original floor pan.
I believe I saw that cab on CL a couple years ago and drooled on the keyboard over it. Glad it went to a good home and is getting an awesome rebirth as a hot rod!
Up to the front of the truck, we decided it was time to channel the grill 3" and section it another 3". The original grill was in very nice shape. It needed a little work on the bottom lip but otherwise had faired quite well over the years.
Very nice work indeed! But considering what you are doing to the truck I suggest that the relevance of a US mail truck is long gone and the thread's title be amended...