So now That All is mostly said and done, I prove once again that my style of fabrication is:
Step 1- Make it once
Step 2- learn from a bunch of stupid mistakes
Step 3- Buy new body panels
Step 4- Start again but avoid stupid mistakes
So that Being said, Ill give you guys a few pointers so you avoid some silly mistakes Like I did. I didn't make all of these mistakes, But I figure I should bring them up so you don't.
First of all your Rad support cutting:
I wish I took pictures, but for some dumb reason I didn't. When I cut my core I measured 9'' straight in from both sides, But I ended up taking a bit too much off to fit my grille centerpiece (it was off a van and I am not to sure if they are a different width than the trucks). I had to trim about 1/2'' off each side of the grille, that being said I would measure 8 1/2'' in at the front side of the rad support. Make sure to measure the width of the centerpiece that you want to use, just to double check
My second mistake is I made a straight cut on the rad support (front to back). What I should have done was make an angled cut to make the back portion of the rad support wider to match up with my fender line. I wont be able to get any measurements until this weekend on that one though.
Fender cutting:
Basically gut out the inside of the fender to clear the cab, you don't have to gut out the front if you don't want to. If you do want to completely gut out the fender make sure to leave lots of metal around the lower mounting spot and around the back and top seams. DO NOT cut any seam unless you are going to remake new mounts. In the first picture I circled out areas that you will want to keep metal for strength. In the second picture I circled where i cut a seam and now my fender is ripping apart, you don't need to cut there at all and I don't know why I did.
It would be a good idea to leave the lower lip on the fender to use when making inner wheel wells. I will be making a canvas one to snap in and out of place for easier work access. You will also need to leave the front portion of the inner fender on so you have an attachment point for your rad support.
Hood cutting:
unless you are good with welding and fabbing on body panels say goodbye to your hinges because you cut out the mount. I am now using hoodpins in all four corners. The hood will also become flimsy, I might suggest a fiberglass hood, but I dont know how that would turn out. Make sure to measure twice and cut once... I didn't and I now have a 1/2''-3/4'' gap on either side of the hood. you will also need to trim the back portion of the hood.
Fitment:
First step is to remove your cowl or cut it ('81 and on), or you will be fighting with it when you put your fenders back on. Next you will need to put the fender on the cab with the lower and top rear bolt hole, and only snug up the bolts. you dont use the inner rear mount on the cowl anymore.
next is to push in at the front like a mofo and basically bend your mounts. from there you can either weld it, or if your off like me cut up some angle iron and bolt it together. I have 2 tabs at the top and one on the bottom. ** one big pointer is to take pictures and triple check the height of the fender to the rad support, I just guessed when I did mine and now my hood sits up too high in the front
Thats all that comes to mind at the moment, Have a happy install!!