Projects The Official "Chop Sewage" Build Thread Start to Finish?

What are your plans for colour and wheels/tyres?

 

Really nice work salty! I may have to get lessons on body work from you.


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About 15 ish hours hand sanding a bunch of small parts, grill spears (5) and corresponding pile of grill parts (4), splash apron, radiator moulding, running boards (2) and both inner fenders.

Total sanding time 150 hours of mind numbing tedious dirty shiet work...I hurt....a lot.

At least when you sand the body it seems like you make progress...now that all the small parts are done (these are luckily ready for their last thin coat of low build primer and then finish paint) I am officially done with the second sand....

Now that all of the parts are out of the cab I'm going to sand the dash and custom made fiberglass hard headliner as well as the inside of the bed...

EDIT***erridently I haven't looked at the thread in awhile....so those that responded! THANKS! and to answer: James D, the color(s) are a waterborne base; Tequila Yellow bottom (with a light pearl added) and Candy Orange top (with a moderate sized metal flake AND a bit more pearl)...wheels and tires I haven't nailed down yet....I am leaning towards either a Radir tri-rib, or full chrome steelies with spider caps...(I posted examples of the colors a few pages back tho computer screen colors don't do it justice)

I Smell Smoke: if you ever want to hate yourself....hit me up you can come soak up some of my OCD body working pain....


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Welcome to my hell, here is the process: top to bottom....
1) what you start with
2) apply a black powder guide coat (yes I could use an aerosol guide coat but it's expensive and you need a lot of it...therefore I use a canned powder guide coat, lots cheaper and works well....the shit gets everywhere)
3) sand all the guide coat off destroying your hands in the process
4) hell in progress
5) what you are left with before you reprime
6) the results of your hard labor...

this job took 11 hours for a total of 161 hrs.

Corrugated steel sucks; my hands went numb, there's a nerve in my left arm running through my elbow that has decided to wage war on my brain and for no explicable reason send an electric shock through my arm at inopportune times....I hate this bed....

Now off to the inner roof and the dash...




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Here's my guide coat...some Italian shtuff I got...I like it and it goes a real long way


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Go man, GO!

Looks real good.

Gettin' close now . . .

 

BWAAAAHAHAHAHA.... If real close means approximately 100-150 more hours to go then yes I'm getting real close....

Tho my shoulders don't think the light at the end of the tunnel is quite close enough yet!

Seriously....even though I have a ways to go....I can actually see it in gloss now...


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Salty I can't wait to see some color laid down. This is going to be nice


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coming along man, keep chipping away. we all know the hard work is worth it in the end.

good looks on the guide dust, I'll be looking into that.

 

Thanks for the kind words guys....I'm ready to be done with this...I just came into the house from sanding the dash (no pics yet) and I am thoroughly beat up...

the guide coat I'm using ain't cheap either at $40 bucks BUT seeing as aerosol guide coat costs $9.99 a can and one can only does one side and a front (or back as it were)....

I plan on sanding four total times all of which I have been laying down guide coat...do the math on that...every time I sand it takes three cans of aerosol guide coat times four equals 12 cans conservatively...that's $120 in aerosol or $40 for the powder...

The powder is a bit more of a pain and can get everywhere if your not careful...but I have found this stuff finds the smallest of flaws as opposed to the aerosol which misses some stuff if you don't have a good overlap...

Here's the link
http://www.eastwood.com/farecla-dry-guide-coat.html

 

I have spent the last 12 hours sanding a roof over my head...whatever I was imbibing on when I decided to make a custom fiberglass hard headliner must have been wicked good...12 hours with a 6lb sander over your head is a long time...The dash is looking super sweet...front fenders resanded and reprimed...

172 hours in.


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The dash and headliner look great! It is nice when someone takes the time to design and build something that not only is different but really works.

 

Looks great and yes body work sucks balls. Man you use a lot of guide coat. I use the aerosol and can get my whole truck done easily with one can with some left over. The panel doesn't need to be completely black just a mist will let you see where the highs and lows are.

 

Funny you should say that (poster above me) I had one of my other buddies say the same thing.... Bottom line I don't know what the deal is cause I don't make the panel black, I mist it on dry...as you should....and still had the same coverage issues....

Is what it is, it may possibly be the brand or it could be that I suck at guide coat application....whatever...I found a solution for whatever the problem may be...


The slot in the middle of the headliner is for a (gasp) over head console where all of my switches and ancillary type stuff will go (airbags, headlights, security lockouts etc)

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As long as you found something that worked. The last thing you want when doing body work is more headaches.

This is not aimed at you per se but some guys don't realize that the dry aerosol guide coats can be rubbed around on the panel just like the stuff in the dish so you don't need complete coverage like if you were using spray paint. I see a lot of guys spraying it on like they are trying to cover the whole panel with paint when all you need is a light mist and then rub it around.

 

Aight, block sanding log fourteen-teen and two thirds...



In the last 15 hours (nearly straight) I have sanded the entire truck for the third time, all body panels, bed, doors, hood, cab, inner bed, dash and custom hard headliner (I will never do that again)....

Now time to re-spray the entire effing truck...



The results of my labors.....(AKA more freakin work...)



195 hours into sanding, my shoulders have revolted, fingers....they might be still there...I don't know, I can't feel them, wrists...who knew they could feel as badly as they do....I would switch hands for a few days but both have failed me...time for a Dr. Pepper...if I could only manipulate my fingers into pouring the beverage...

In theory I only have one sanding left...and for the most part I believe that to be true, there is a few problem areas that I will have to address prior to sanding the last time; nothing major and all having to do with gap fitment in the doors....the smoother it gets the more the minor flaws pop...which is the point...

After I realized what I had gotten myself into I revised my projected time to completion to 250 hours (just for block sanding that is) if all goes well I should be right on the money time wise.


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Looks really nice!!

 

Thanks K13....here's my time sheet as it were....

Block sanding time log

Date Hours Location
08-22-13 3 Roof
08-23-13 2 Finished roof/did tonnoue cover
08-24-13 1 Windows front/back
08-30-13 7 Roof/belt line
09-02-13 2 Roof
09-10-13 3 Inside of hood
09-10-13 1 Inside of hood
09-11-13 1 Inside of hood
09-17-13 2 Outside of hood
09-18-13 3 Hood/fender
09-19-13 2 Hood
09-26-13 2 Driver fender
09-28-13 2.5 Driver fender
09-29-13 3 Passenger fender
09-30-13 1.5 Dog legs
09-30-13 1 Fenders
10-07-13 2 Driver door/B pillar
10-07-13 1 Passenger door/B pillar
10-08-13 11 Door jams/Driver door
10-15-13 3 Passenger Door
10-25-13 3 Passenger Door
10-27-13 4 Passenger Door/Top of passenger bed
10-28-13 2 Passenger Door
11-02-13 5 Passenger Bed
11-08-13 2 Passenger Bed
11-13-13 4 Passenger Bed
11-14-13 2 Passenger Bed
12-10-13 5 Tailgate
12-11-13 2 Tailgate
12-12-13 1.5 Tailgate
12-16-13 3.5 Tailgate/roll pan
12-17-13 6 Tailgate/passenger bed
12-18-13 3 Tailgate/passenger bed
01-10-14 2.5 Running board
01-11-14 1.5 Running board
01-13-14 2 Running board
END OF FIRST SANDING

01-19-14 1.5 Roof
01-21-14 1.5 Roof
02-06-14 2 Jams
02-15-14 5 Cab
02-16-14 1 Cab
02-17-14 3 Doors/driver bed seam cut ins
02-24-14 4 Driver bed/tail & pass bed cut in
02-26-14 6 Pass bed/tail
03-03-14 5 Front clip
03-04-14 6 Spot sand whole truck/re-prime whole truck
END OF SECOND SANDING

03-25-14 4 Running boards
03-26-14 2 Grill spears
03-27-14 3 Grill spears
03-28-14 4 Radiator shroud/inner fenders
04-02-14 5 Inner bed
04-03-14 3 Inner bed
04-04-14 3 Re-prime inner bed/inner fenders/grill/radiator cvr/grill apron
04-05-14 2 Dash
04-06-14 2 Hard headliner
04-20-14 3 Hard headliner/ dash
04-21-14 4 Hard headliner, re-prime dash/hard headliner & front fenders
04-29-14 3.5 Hood/fenders
04-30-14 6.5 Roof/jams/started pass. bed side
05-01-14 8.5 Tailgate/driver bed/headliner/dash
05-02-14 4.5 Re-prime truck inside & out
END OF THIRD SANDING

195 hrs




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I wasn't going to put another coat of primer on this as I told myself "self...this is the inside of the hood...no one will look at it as it will never be open (ruins the lines of the truck with the hood open IMHO) so I don't care if it has a flaw or two..." BUT my OCD took over and 5 hours later I re-sanded the few flaws that were there out and gave it another coat of primer...did the steering column as well....glutton for punishment I am...200 hours in.


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Extremely nice work!!! Hats off to you.

 

Hi Salty.When you are done with this epic feat of sanding,are you going to have any finger prints much less fingers left?Looking good.
Good luck.have fun.Be safe.
Leo

 

Thanks guys....and to answer your question Woodbutcher....probably not...fingerprints and non-sore extremities are a thing of the past it seems....should be worth it though from what I can tell....she sure is lookin sexy...

 

Wet sanding officially in full swing...13 hours into pruney fingers...hood done once already and subsequently re-coated (not there yet), inner fenders, grill, radiator shroud, both fenders and both doors done and should be ready for sealer (gotta look at them in the light and make sure they make the cut...)

cab and bed next...



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Been a bit since an update....I have not gotten as much done as I would have liked over the last month...I had grand plans to be painting gloss by now (family was out of town for three weeks) and to finish up the last sanding, seal and start slingin the pretty stuff....

Well as luck would have it the interdepartmental transfer I have been working towards came through right before the fam left and I spent the month working my arse off (now the new guy again....gotta prove your salt dontchaknow...) and worked a metric crap ton....AKA I spent my time working and sleeping...I did get the bed wet sanded once more...(pictured)

The last two days I got the final sandings done on the inside of the doors and the inside of the hood...and just laid the sealer down...AKA I don't have to mess with em anymore (till gloss anyway)

Summary, 259 hours in (I was hoping to be painting at 250 hours) the good news...one last wet sand and the sealer is going on...stay tuned....it's about to get real!




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That bed looks as smooth as glass. Good work. Your on the home stretch


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Thanks buddy....it better be...I am quickly finding out that everyone was right...(on two counts)

First:
Triple the amount of time and dollars you think it will take to finish...

I haven't tripled the amount of dollars (actually going to be coming in under what I thought) however I have solidly tripled the time...before I started sanding I "guessed" that I would be block sanding for 100 hours...I also guessed "about" four complete sanding go rounds...the front fenders are going to be good at four...the cab 5...the hood 6, and the bed 5 (the bed cover one....but it doesn't count cause it was a piece of perfect brand new steel.

Seeing as I made a postulation as to what I thought my time would be I have kept track of all my time sanding...I am solidly at 261.5 hours....right inline with finishing up sanding at 300 hours.....thanks dad (for telling me the rule).

Second:
I don't remember who said it (on the board here) but he stated "sand till you get sick of sanding....then sand two months more..."

I got sick of sanding six months ago....but I am too OCD to quit...

It really is coming together though...it looks sweet mocked up (wait till I show ya the door jambs....they are works of art....and my hands hate me for them).

The trick is to keep all the various parts separated and un dinged until I can get gloss on em...I am actually storing parts at my neighbors house to get them out of the way as they get done...yea...three car garage and I don't have enough room...whatever...


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I just realized I have been block sanding for 10 months/267 hours/16,020 minutes/961,200 seconds...and this is the last run of it...praise The Lord Mr. Ford....front fender and doors DONE...



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More block sanding...roof and bed again...nothing real remarkable other than a lot of dirty work....

285 hours in...

All needed areas have now been spot primed and one last going over with the ultra long board and one last guide coat and we should be ready for sealer....




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Great job. I love the body lines on this truck.

 

The bed on that thing is an amazing piece of work!