Project Rolling Thunder Part 11 - Body Work Secrets

(ANNOUNCER)>> TODAY IT'S OLD SCHOOL ALTERED BODY WORK SECRETS FOR PROJECT ROLLING THUNDER. NOW THAT RYAN HAS PUSHED OUR RACE TRACK FORD RANGER'S FRONT AXLE FORWARD BY SIX INCHES, IT'S UP TO KEVIN TO MAKE THE FENDERS FIT. IT'S ALL TODAY HERE ON TRUCKS.

(RYAN)>> HEY GUYS, WELCOME TO TRUCKS. TODAY WE'RE BACK ON PROJECT ROLLING THUNDER, OUR SUPERCHARGED FOUR POINT SIX LITER VEIGHT, SIX SPEED MANUAL TRANSMISSION EQUIPPED COMPACT PICK UP TRUCK. NOW THIS THING'S ALSO GOT AN '03 MUSTANG COBRA INDEPENDENT REAR SUSPENSION, CUSTOM FRONT SUSPENSION, AND SOME PRETTY BIG BRAKES UP FRONT. NOW WE DID ALL THIS WITH THE END GOAL OF HAVING THIS LITTLE FORD PICK UP HANDLE MORE LIKE A MUSTANG, AND A BIG PART OF THAT IS WEIGHT BALANCE. NOW IT'S NO SECRET THAT ALL PICK UP TRUCKS ARE EXTREMELY WEIGHT BIASED TOWARDS THE FRONT OF THE VEHICLE. SO TO ALLEVIATE THAT PROBLEM WE HAD TWO CHOICES. WE COULD MOVE THE ENGINE AND TRANSMISSION BACK INTO THE CAB, DO SOME MAJOR FIREWALL SURGERY, OR WE COULD MOVE THE FRONT SUSPENSION FORWARD ESSENTIALLY HAVING THE SAME EFFECT, AND THAT'S THE ROUTE WE TOOK. WHILE IT DID HELP WITH WEIGHT BALANCE, WELL IT ALSO CREATED ANOTHER PROBLEM. AND THAT PROBLEM IS THE FRONT TIRE'S GONNA WANT TO OCCUPY THE SAME REAL ESTATE AS THE FENDER, AND IT LOOKS LIKE WE'RE GONNA HAVE TO COME IN HERE AND TRIM SOME OF THIS INNER STRUCTURE AS WELL. NOT ONLY THAT, WE'RE GONNA HAVE THIS VAST EXPANSE BEHIND THE FRONT WHEEL. BUT IN THE LONG RUN IT'LL ALL BE WORTH IT AND PAYOFF BIG TIME. AND EVEN BETTER YET, IT'S NOT MY PROBLEM.

(KEVIN)>> THAT'S RIGHT, THE PROBLEM'S MINE. AND BY THE OUTWARD APPEARANCE, IT LOOKS LIKE A BIG ONE BECAUSE THE INNER STRUCTURE'S NO BIG DEAL. WE CAN TRIM IT OUT, WE CAN EVEN TUB IT LIKE THE MINI TRUCK GUYS DO, BUT THE OUTSIDE, NOT SO MUCH. WE'VE GOT A LITTLE BIT OF SPACE HERE AND NOTHING HERE. IF WE WERE GOING IN A STRAIGHT LINE AND NEVER EVER STEERING, MAYBE NOT SUCH A PROBLEM, BUT THIS TRUCK IS GONNA GO TO AUTOCROSSES, IT'S GONNA GO THROUGH TWISTIES AND WINDIES. WE NEED TO HAVE LOCK TO LOCK CLEARANCE ON THE TIRES OBVIOUSLY. NOW WHAT WE CAN DO IS ACTUALLY A VERY SIMPLE SOLUTION. AND SINCE THIS IS A SINGLE WALLED SHEET METAL PANEL, IT'S GONNA BE QUITE EASY TO DO. HANG IN THERE AND WE'LL SHOW YOU. THE OTHER THING IS THESE LMC PANELS ARE A NICE QUALITY STAMPING AND THEY'RE RELATIVELY INEXPENSIVE. THEY'RE JUST UNDER $100 BUCKS A PIECE. SO WHAT WE'RE GONNA DO IS SHOW YOU HOW TO SACRIFICE AN ADDITIONAL FENDER, MOVE YOUR WHEEL ARCH FORWARD, DO A NICE BUTT WELD, METAL FINISH IT, AND BY OUTWARD APPEARANCES YOU'RE NEVER GONNA KNOW THE DIFFERENCE.

WITH THE GAP SET AND THE FENDER LOCKED INTO PLACE, WE CAN START THE TRIMMING PROCESS, WHICH BEGINS WITH THE WHEEL ARCH. SINCE IT'S FLARED OUT, WE ACTUALLY NEED A FLAT SURFACE TO WORK AGAINST.

NOW WITH THE SECOND FENDER ON A BENCH TOP, I CAN START TRIMMING FOR THE PATCH. NOW KEEP IN MIND I'M TRIMMING WAY PAST MY ACTUAL CUT LINE. NOW THE REASONS FOR THIS ARE TO BE CLEAR IN ABOUT A MINUTE. BUT TRUST ME, YOU WANT TO PAST WHERE YOU ACTUALLY WANT TO SLICE AND SECTION YOUR FENDER. ON THE DOOR GAP I'M CUTTING A QUARTER OF AN INCH IN. THIS GIVES ME A FLAT PART OF THE PANEL THAT I CAN BUTT WELD AGAINST THE OTHER PANEL. THE INNER FENDER BRACE IS ALSO TRIMMED SO IT DOESN'T INTERFERE.

NOW HERE'S WHERE IT BECOMES CRYSTAL CLEAR EXACTLY WHAT WE'RE DOING. WE'RE TAKING A PAGE OUT OF THE OLD SCHOOL ALTERED WHEEL BASE DRAG CAR BOOK AND LITERALLY MOVING THE WHEEL ARCH FORWARD TO MATCH THE NEW LOCATION OF THE WHEEL CENTER LINE. NOW RIGHT NOW AT THIS STEP IT'S NOT AN EXACT SCIENCE, SO YOU WANT TO TRIM A LITTLE AT A TIME. ONCE YOU'RE HAPPY WITH THE OVERALL LOOK AND FEEL OF THE NEW WHEEL ARCH LOCATION, WELL HERE'S WHERE I MARKED THE SPOTS AND THEN I CAN DOUBLE CHECK WITH A PLUMB LINE LATER. MY MASKING TAPE IS GOING TO HOLD THE FENDER IN PLACE WHILE I MEASURE. IF YOU'VE GOT AN EXTRA SET OF HANDS, WELL YOU CAN USE A BUDDY. RYAN'S HIDING RIGHT NOW.

MY PLUMB LINE SHOWS ME THE EXACT AXLE CENTER LINE, AND THIS WAY I CAN LITERALLY MEASURE THE WHEEL ARCH AND CENTER UP THE FENDER. I'M ALSO USING THE UPPER STYLE LINE AS A GUIDE. NOW ONCE I'M HAPPY WITH THE LOCATION, I'M USING SELF DRILLING PHILLIPS HEAD SCREWS WE GOT FROM INDUSTRIAL DEPOT TO LOCK MY NEW WHEEL ARCH INTO PLACE. NOW WITH IT SCREWED INTO PLACE, I CAN LITERALLY STEP BACK AND DOUBLE CHECK THE PROPORTION CAUSE EVEN THOUGH THE MEASURING TAPE SAID IT'S CENTERED, IT STILL HAS TO LOOK RIGHT.

(ANNOUNCER)>> UP NEXT, WE'LL FIT THESE TWO FENDER PIECES TOGETHER TO MAKE ONE SEAMLESS BODY PANEL. AND LATER, KEVIN WILL DO AWAY WITH THE UGLY REAR BUMPER AND SMOOTH IT ALL OUT WITH A ROLL PAN, STAY TUNED!

(KEVIN)>> HEY WELCOME BACK TO TRUCKS. WE'RE WORKING ON OUR ALTERED WHEEL BASE FORD RANGE, BUT IT'S NOT AN ALTERED WHEEL BASE IN THE TRADITIONAL SENSE. OUR IS FOR WEIGHT TRANSFER, BUT IT'S A DIFFERENT TYPE. SINCE RYAN JUST MOVE THE AXLE CENTER LINE FORWARD FIVE ENGINES TO LITERALLY CHEAT THE ENGINE WEIGHT BACK AND GET A BETTER BALANCE WITH THE TRUCK. SO MY JOB WAS TO MOVE THE FENDERS AND MATCH THAT WHEEL BASE. SO WE'RE USING TWO FENDERS TO MAKE ONE AND SACRIFICING BOTH OF THEM, AND MOVING THE WHEEL ARCH FORWARD FIVE INCHES TO MATCH THE AXLE CENTER LINE. SO WE'RE ALMOST READY TO START CUTTING AND TRIMMING FOR OUR FINAL FIT SO WE CAN WELD IT UP, BUT CHECK THIS OUT. YOU'LL NOTICE THAT THE STYLE LINE VALLEY ON THIS UPPER FENDER IS SLIGHTLY LOWER THAN THE ONE ON THE BOTTOM FENDER. THAT'S NOT A MISTAKE, IT'S INTENTIONAL, HERE'S WHY. THE WIDTH OF MY BLADE IS GOING TO COME INTO PLAY. IT'S 40 THOUSANDTHS AND WHEN I MAKE MY CUT ACROSS THE TOP THROUGH BOTH PANELS, SOME METAL'S GOING AWAY, AT LEAST 40 THOUSANDTHS OF AN INCH. AND WHEN I DRAW MY PANELS TOGETHER FOR A NICE BUTT WELD, A PLUSH FIT, WELL THESE STYLE LINES ARE THEN GONNA MATCH. SO IT'S COMPENSATING FOR THE WIDTH OF THE BLADE. THAT WAY I GET A NICE PERIMETER FIT WITH VERY LITTLE GAP THAT I DON'T HAVE TO FILL UP WITH A BUNCH OF WELDING.

NOW FOR THIS PROCEDURE I'M CUTTING BOTH PANELS WITH A SINGLE CUT, AND I'M STARTING FROM THE INSIDE, WHICH DOES A COUPLE OF THINGS FOR ME. IT SHOWS ME EXACTLY WHERE I NEED TO MAKE MY CUT FROM THE OUTSIDE AND NOT OVER CUT, AND IT ALSO GIVES ME A PRECISE CUT OF BOTH PANELS. NOW I'M MARKING MY CUT LINES ON THE OUTSIDE WITH BLUE FINE LINE TAPE AND DOING A REINFORCEMENT TRACE WITH A SILVER INK PEN. THIS WAY IF THE TAPE GOES AWAY I STILL HAVE A CUT LINE. NOW WE'VE SPED THE VIDEO UP FOR OBVIOUS TIME REASONS BUT TRUST ME, I'M NOT FORCING THE BLADE AND YOU DON'T WANT TO EITHER. LET THE BLADE FIND A NATURAL PROGRESSION ON ITS OWN. THAT WAY YOU'RE NOT GONNA DISTORT THE METAL OR PREMATURELY WEAR YOUR BLADES OUT. NOW HERE'S WHERE YOU REMOVE FENDER NUMBER TWO AND CAREFULLY SET IT ASIDE. THEN YOU CAN TAKE THE SKIN OF FENDER NUMBER ONE AND SAY GOODBYE FOREVER. NOW YOU CAN TEST FIT YOUR NEW WHEEL ARCH. WHEN YOU'RE HAPPY WITH THE FIT, YOU CAN CLEAN UP THE OUTSIDE BUT NOTICE I'M NOT TRIMMING TOO MUCH OF THE ECOAT OFF. THIS HELPS YOU WITH SITING IN YOUR BODY WORK LATER ON. NOW MAGNETS AND CLAMPS HOLD THINGS IN PLACE WHILE I GET ROUGH TACKS SET DOWN AND LOCK EVERYTHING INTO ITS FINAL POSITION, BUT I'M NOT GONNA FINISH WELD THINGS JUST YET. OKAY, WITH OUR SECTION FENDER MOUNTED SECURELY ON THE MATCO SUPER STAND, THERE'S A COUPLE OF THINGS I WANTED TO SHOW YOU BEFORE I CONTINUE WITH THE WELDING PROCESS. REMEMBER THE LINE THAT I DREW IN THE VALLEY OF THIS BODY STYLE LINE WHERE THE INSERT PANEL WAS OBVIOUSLY LOWER THAN THE ORIGINAL FENDER THAT WE'RE USING AS OUR BASIS. NOW SINCE I COMPENSATED FOR THE WIDTH OF THE BLADE, NOW THESE LINES MATCH UP PERFECTLY. SO A LITTLE BIT OF FORE THOUGHT GOES A LONG WAY WITH A PROJECT LIKE THIS. NOW HERE'S THE BEAUTY OF CUTTING BOTH PANELS WITH ONE BLADE AT THE SAME TIME. LOOK AT MY FIT, IT'S LITERALLY PERFECT. IT'S ALMOST IMPOSSIBLE TO MAKE A MISTAKE CUTTING LIKE THIS AND IT SETS IT UP FOR A PERFECT UNION OF BOTH PIECES OF SINGLE WALLED SHEET METAL. AND IF YOU HAD CUT THEM INDEPENDENTLY AND CONSTANTLY TRIMMED, SOONER OR LATER YOU'RE GONNA RUIN YOUR FIT AND RUIN BOTH PANELS. NOW ALL I HAVE TO BATTLE IS HEAT.

NOW THE PROCESS OF TACKING AND FINISH WELDING STARTS BUT YOU'LL NOTICE I'M NOT WELDING VERY FAR OR VERY MUCH BEFORE I COME IN WITH A HAMMER AND DOLLY. THIS GIVES YOU THE OPPORTUNITY TO PUT YOUR METAL BACK WHERE IT WANTS TO BE AND ELIMINATE THE HEAT DAMAGE THAT YOU'VE CREATED WITH THE TACK WELDS. YOU CAN KEEP CONTROL OVER YOUR SHEET METAL BY STOPPING AND STARTING AND SITING. IT'S ALSO WHERE LEAVING YOUR ECOAT OR AS MUCH OF IT AS POSSIBLE IN PLACE HELPS, BECAUSE EVEN THOUGH IT'S NOT SHINY LIKE PAINT, IT STILL HAS A BIT OF A GLOSS AND YOU CAN LITERALLY READ THE SURFACE AND TELL WHERE YOUR DISTORTION IS. NOW WITH SHEET METAL YOU WANT TO STAGGER YOUR WELDS AS MUCH AS POSSIBLE. JUMP AROUND AND KEEP THE SPACE BETWEEN THEM UNTIL YOU FINALLY HAVE A CONTINUOUS WELD TO MATE UP TO YOUR INDIVIDUAL TACKS. AND THEN YOU CAN PROCEED TO FLUSH FITTING OR GRINDING THE WELDS FLAT. NOW I'M USING A 24 GRIT DISC ON AN ANGLE GRINDER. AND EVEN WITH THE VIDEO SPED UP, YOU CAN SEE WHAT A LIGHT TOUCH I'M USING BECAUSE YOU CAN GENERATE ALMOST AS MUCH HEAT WITH A GRINDER AS YOU CAN WITH A WELDER. SO BE CAREFUL!

(KEVIN)>> HEY, WELCOME BACK. WELL AFTER SOME MORE WELDING AND A LOT MORE HAMMER AND DOLLY WORK, OUR FENDER IS FINALLY READY FOR A SKIM COAT OF FILLER AND THEN PRIMER, AND FINALLY PAINT. AND AS YOU CAN SEE, THE PROPORTION DOESN'T LOOK GOOFY AND IT FITS WITH OUR STRETCHED WHEEL BASE PERFECTLY. BUT THERE'S STILL ONE MORE SHEET METAL PROJECT WE'RE GONNA DO TODAY. AND THAT IS PUTTING A ROLL PAN ON THE BACK OF ROLLING THUNDER. NOW THIS IS A STEEL ROLL PAN AND IT CAME FROM LMC TRUCK, AND IT SHIPS WITH ALL THE HARDWARE IT TAKES TO BOLT IT IN PLACE. OR YOU CAN WELD IT, FINISH THE WELDS OUT FOR A NICE COOL CUSTOM LOOK. I'LL GIVE YOU ONE GUESS AS TO WHAT WE'RE GONNA DO.

THE STAMPED HOLES IN THE ROLL PAN ARE THE PERFECT PLACE TO TACK IT TO THE BED. GRINDING THE SURFACE OF THE PAINT OFF IS GONNA GIVE YOU A GOOD SOLID WELD, AND THE DUPLICOLOR WELD THROUGH PRIMER GIVES ME SOME CORROSION PROTECTION.

PANEL CLAMPS HOLD THINGS IN PLACE UNTIL I CAN WELD. AND THEN I CAN INSTALL THE TAILGATE AND DOUBLE CHECK MY FIT. ( )>> SUPER!

(KEVIN)>> THANK YOU! WITH THE TOP OF THE ROLL PAN HELD IN PLACE, NOW WE CAN FIT AGAINST THE BED SIDES. AND LIKE ANY USED VEHICLE, THIS ONE'S HAD A COUPLE OF PRIOR REPAIRS. THE PASSENGER'S SIDE, WELL WE CAN JUST TACK THAT INTO PLACE AND FIT IT IN LATER. BUT THE DRIVER'S SIDE, WELL YOU CAN SEE THE FILLER WE UNCOVERED AND THERE'S AN EXCESSIVE GAP. SO WE'RE GONNA USE ANOTHER OLD SCHOOL CUSTOM TRICK AND USE A PIECE OF TIG ROD. BACK IN THE DAY, THEY LITERALLY USED COAT HANGERS TO FILL IN THESE GAPS, BUT IT'S THE SAME PRINCIPLE. YOU'RE BASICALLY USING A FILLER METAL AND TACKING IT INTO YOUR SHEET METAL TO FILL UP THE GAP INSTEAD OF CHEATING AND USING PLASTIC FILLER.

THIS IS A PROCESS, AGAIN, OF CONTROLLING YOUR HEAT. SO MAKE SURE YOU TAKE YOUR TIME BETWEEN TACKS AND LET YOUR WELD POOL COOL DOWN. NOW WHAT I'M DOING RIGHT NOW MIGHT SEEM LIKE BREAKING MY OWN RULES, BUT HERE'S WHY I CAN GET AWAY WITH IT. THE ROLL PAN ITSELF IS A HEAVY GAUGE SHEET METAL. THE BED SIDE IS A CORNER. BOTH PANELS ARE CURVED. NOW ALL OF THOSE THREE THINGS TOGETHER GIVE YOU A LOT OF STRENGTH EVEN WITH SINGLE WALLED SHEET METAL. SO YOU CAN POUR A LITTLE MORE HEAT TO IT AND STACK UP YOUR WELDS LIKE I'M DOING HERE WITHOUT A LOT OF DISTORTION. WITH THE GAP FINALLY FILLED, YOU CAN GRIND YOUR WELDS FLUSH AND IT GETS YOU READY FOR A SKIM COAT OF BODY FILLER. NOW OTHER THE OTHER SIDE WE HAD A LOT BETTER GAP WITH A MUCH SMALL SPACE, SO I CAN KEEP MY WELDS A LOT SMALLER. THIS OF COURSE MINIMIZES ANY DISTORTION AND ALLOWS YOU TO CONTROL YOUR WELD MUCH BETTER. NOW AFTER THE WELDING'S DONE, JUST LIKE ON THE FENDER PROJECT, I'M USING A 24 GRIT GRINDING DISC. NOW THAT'S A VERY, VERY AGGRESSIVE TOOTH FOR GRINDING BUT IT ACTUALLY HELPS KEEP THE METAL COOL BECAUSE IT REMOVES MUCH MORE MATERIAL WITH A LOT LESS EFFORT. A FIBER WHEEL CLEANS THE WELD CONTAMINATION UP AND WE'RE READY FOR FILLER.

TADA!

(RYAN)>> HEY GUYS, WELCOME BACK TO THE SHOP. WELL KEVIN'S GOT SOME EPOXY PRIMER SPRAYED OUT ON THE FRESHLY STRETCHED FENDER. NOW IT'S READY FOR BODY WORK. NOW I'VE GOT TO SAY, ONCE THIS THING'S UNDER FINAL PAINT, I DOUBT YOU'D EVER BE ABLE TO TELL THAT THAT FENDER'S BEEN MODIFIED. NOW WE'VE BEEN PUSHING THIS TRUCK AROUND THE SHOP ON A MISMATCHED SET OF WHEELS JUST TO KEEP IT MOBILE AND ALLOW US TO MOVE IT AROUND, BUT NOW WE'RE READY FOR THE REAL SET OF TIRES AND WHEELS. WE PICKED UP THESE BEAUTIFUL FORGED 18 BY 10 INCH THREE PIECE WHEELS FROM TRUE FORGED. NOW THE HOOPS THEMSELVES ARE ROTARY FORGED AND FIRED, AND THE CENTER SECTION IS BOLT IN, AND IT'S CUT FROM A SOLID CHUNK OF FORGED BILLET. NOW THIS IS THEIR FORMULA STYLE. WE WENT WITH POLISHED SPOKES AND A POLISHED LIP, BUT THEIR ONLINE WHEEL EDITOR HAS HUNDREDS OF CHOICES. YOU CAN CHOOSE THE STYLE, TRIM FINISH, SIZES, AND OFF SETS. NOW AS FAR AS RUBBER GOES, THESE ARE 295/35 18 BFG KDW'S, AND THIS IS ACTUALLY A PRETTY WIDE TIRE. IN FACT IT'S JUST SLIGHTLY NARROWER THAN THE 305/35 THAT'S ON THE MOCK UP WHEEL. BUT AS WIDE AS THIS TIRE IS, IT'S FOR THE FRONT. THAT'S BECAUSE WE GOT SOME SERIOUS RUBBER FOR THE BACK END OF THIS TRUCK. I'M TALKING CORVETTE AND VIPER TERRITORY HERE. THESE 335/30 18'S ARE WRAPPED AROUND AN 18 BY 11.5 INCH WHEEL. NOW THEY'VE GOT A GREAT LOOKING DIRECTIONAL TREAD PATTERN, GOOD SOFT TREAD COMPOUND, AND ENOUGH VOIDS AND SIPING TO PROVIDE DECENT TRACTION IN THE WET AND GREAT TRACTION IN THE DRY. THESE THINGS OUGHT TO DO GREAT OUT ON THE STREET. NOT TO MENTION THEY'RE GONNA LEAVE SOME PRETTY NASTY LOOKING WIDE STRIPES ON THE ROAD WHEN WE DUMP THE CLUTCH IN THIS TRUCK AT 5,000 RPM.

(KEVIN)>> NOW THAT IS ONE WICKED STANCE. SO YOU CAN GO TO TRUE FORGED WHEELS DOT COM AND DESIGN YOUR OWN TWO OR THREE PIECE FULLY CUSTOM WHEELS, OR CHECK OUT THEIR NEW LINE OF CAST WHEELS FOR EVEN MORE OPTIONS. FOR US, NOW WE'VE GOT TO DESIGN SOME KIND OF CUSTOM FRONT AIR DAM WITH A SPLITTER SINCE THIS PIECE OF MACHINERY IS DEFINITELY GONNA SEE SOME TRACK TIME. I LOVE THIS THING.

(RYAN)>> HEY GUYS, IF YOU'RE LOOKING TO ADD SOME EASY, AND MORE IMPORTANTLY CHEAP, HORSEPOWER TO YOUR VEHICLE, WELL YOU NEED TO CHECK INTO NITROUS. AND SOME OF THE MANY SYSTEMS AVAILABLE FROM NOS OR NITROUS OXIDE SYSTEMS. THESE GUYS HAVE SYSTEMS IN KITS FOR EFI AND CARBURETED APPLICATIONS, SUPERCHARGER AND TURBO SYSTEMS, EVEN DIESEL APPLICATIONS, ALONG WITH ALL THE OTHER SUPPORTING PRODUCTS AND HARDWARE. NOW NITROUS IS ESSENTIALLY A CHEMICAL SUPERCHARGER FORCING MORE AIR OR OXYGEN INTO THE COMBUSTION CHAMBER. AND DESPITE WHAT YOU'VE SEE IN THE MOVIES, THE STUFF IS NOT FLAMMABLE AND IT'S NOT GONNA DOUBLE YOUR ENGINE'S RPM REV LIMIT EITHER. HEY GUYS, THANKS FOR WATCHING TRUCKS, SEE YOU NEXT WEEK. IF YOU'VE GOT ANY QUESTIONS ABOUT ANY OF THIS STUFF, GO TO POWERBLOCK TV DOT COM.