From a rusted mess to a brand new truck

As a kid, I always wanted a ’96 F350. The market is filled with over-priced and half-heartedly done trucks. Over so many builds in my life, I never did my own. 27 years with hands on cars and trucks daily, and with the 5 children getting a little older, I knew it was time. I had been looking and found a truck suitable for a restoration. Bad shape but mostly original. When the wife and kids saw it, they asked if I was really buying it. My first step was to make sure the 7.3 diesel oil faithful was running good. I did remove the pesky fuel bowl for an irate diesel set up and return. A little bigger turbo and intercooler went in. 2 new batteries mean green starter and alternator would made her dependable again. Then, minor stuff lines, power steering, compressor, and new Blistein shocks. Then, I was in need to find a bed. In New England the salt destroys. In the middle of winter, a bed showed up online down in southern Delaware. It had a great floor. The wife and I went for the trip. Once back , knowing I had Ford bed sides, new in box above the booth, I went to work cutting the sides off. I sandblasted, recoated, re-epoxied, then enameled the inners and floor along with everything else that would receive top coating. Seam sealer, it was a huge task. Even the inner bed side was coated, epoxied, and enameled all the way through. No expense speared here. Next, good cleaned fenders, same procedures and the absolute best chemicals were used. Then, hood, then, doors. Once this was completed, I was ready to stop driving and take her apart. By this point, there is no Bondo anywhere, lots of tear down and rusty old bolts. The existing fender hood doors and bed were thrown out. The cab floor had a major hole. The inner and outer rockers were completely gone. Once off, I sandblasted everything. I did the same paint procedures after sandblasting, but I put bed liner on outer cab floor. I used structural adhesive for the floor, along with spot welding to keep it original looking. While I had a rolling chassis, I did completely new fuel lines, fuel pick up screens, selector valve, and 2 new tanks painted blue. I sandblasted frame and used Por-15 with top coat. A new radiator support, new mounts and hardware. While the motor was out, we did the oil pan and oil cooler with a new block heater. New drive shafts and exhaust as well. Red head steering box, new shaft, new transfer case shifter, oil and tranny dip stick tubes, and tranny lines. Next up, reassemble it all. First line of business was to clean up the look of all the wires every which way over the years into a clean line. The bench seat was reupholstered in grey leather. A new headliner, rug, and door trim panels finished the interior. I put special attention to the 4WD shifter, insuring it will almost certainly never leak or rust around the edge of the floor. It is the cleanest ’96 I’ve seen. No Bondo anywhere. Even the seam sealer matches OEM sprayed, beaded, and lined. The cluster screen was changed along with the gear selector as well. While there, the inner color bushings were done. New chrome bezels, grill, and all exterior lights made the outside look fantastic. Even a Ford step pad for the rear bumper, which wasn’t cheep.