file 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"

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01 Feb 2015 15:18 #361 by oestek
oestek replied the topic: 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"

Kevin Oeste
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11 Feb 2015 10:08 #399 by oestek
oestek replied the topic: 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"
The bed needed to be re-worked to sit on the new frame and match the body lines of the cab. Adam carefully cut the cross-braces from the bottom of the bed, then welded in new steel to reinforce the supports.



This channel allowed for the bed to sit lower on the frame.



New bed supports were attached to the Lightning frame to match the ‘69 bed mounts.




Kevin Oeste
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21 Feb 2015 18:47 #484 by oestek
oestek replied the topic: 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"
You know how these things go, you solve one challenge and another pops up. This time, the fuel tank needed to be shortened to fit the shorter wheelbase.

We ordered a new tank so that we were not cutting and welding on a tank that once held fuel. That’s just something we don’t do in our shop, especially when a new replacement is around $200.00.





The tank would have to be about this long to clear the axle.



We cut the tank, and Adam TIG welded in a new side. We estimate we only lost a couple gallons of total capacity, and all the original fuel pump, sender, and line fittings connect right up.






Kevin Oeste
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08 Mar 2015 13:42 #629 by oestek
oestek replied the topic: 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"
The Lightning chassis has a longer nose than the ‘69 F100 Ranger, so the next task was to shorten the front frame horns and create mounts for the 1969 bumper. The Lightning frame can be seen sticking out in this initial test-fitting photo from the beginning of the project.



After measuring, Adam removed the front of the frame horns and created a stepped mount that would attach to the bumper brackets.










Kevin Oeste
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08 Mar 2015 13:42 #630 by oestek
oestek replied the topic: 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"
The lightning frame was also slightly lower than the Ranger, so the brackets were adapted to bring the bumper height to its proper position on the Ranger.









Once mounted and aligned, everything looks factory original and correct for 1969.


Kevin Oeste
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25 Apr 2015 17:03 #820 by oestek
oestek replied the topic: 1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"
The Ford Lightning required several coolers, including the radiator, steering cooler, transmission cooler, and a supercharger heat exchanger. Adam fabricated a series of mounts and close out panels to stack all the coolers in the nose of the ‘69. He used a Mittler Brothers bead roller, box pan brake, and punch and flare set to add contours to the panels as well flared holes for strength.









Here, he uses an HTP Versa Spot welder to weld the pieces together.


Kevin Oeste
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