Background When all the bodywork is complete, the fiberglass shell and adjoining door jam seams are primed. In most cases, the final paint is applied immediately after the primer, but we have decided to pause a while. This provides the time to double check all the functionality and to pressure test...
Continue reading...Fiberglass Shell
Bodywork
Background Refer to body seams. Basically bodywork involves a lot of repetitive sanding, filling, and priming to get a smooth surface.
Continue reading...Body seams
Background With all the fiberglass shells now in place (except for the tailgate outer skin), a number of major seams and edges need to be filled and smoothed to fit the body contours. roof top skin at rear window surround [fiberglass to steel sheet metal] roof seam channel ends and drip...
Continue reading...Cab surround fitment
Background The fiberglass cab surround with the rear window is one of the more challenging fitment tasks. Refer to roof skin cut details of the “metal sandwich” that the leading edge of the cab surround must fit into, as well as the third brake light post covering customization and the rear...
Continue reading...License roll pan cover
Background The rear roll pan cover extends under the tailgate and contains an slanted indent for the license plate. The rectangular indent just accommodates a standard 6×12″ U.S. plate and there isn’t enough room left for most license frames. The Smyth Ute kit includes two LED license plate lights that, when...
Continue reading...Panel fitment step 2
Background Review panel fitment step 1 and harvesting of the fender edge strip before proceeding. Positioning the quarter panel fiberglass shells is difficult because there are few “hard” reference points. The two door tabs must match the B-pillar raised surfaces and the front edge should be aligned with the door, but...
Continue reading...Gas filler lid
Background The right fiberglass quarter panel is designed to incorporate the original gas filler lid assembly. This assembly includes a remote lid release latch and a rubber surround for the filler pipe/gas cap. The fiberglass lid seat profile is close to the plastic original, but not quite. It is difficult to...
Continue reading...Panel fitment step 1
Background At this point in the build, all the aluminum pieces have been installed except 1) the rear roll pan bottom bracket, 2) a spacer that fits between the front wall and the fiberglass cab surround, 3) side rail top caps, and 4) the truck bed floor. The tailgate has also...
Continue reading...