First Restoration (W100): Need "for Dummies" advice

[arcking]

A friend of mine has what I believe to be a 1958 Dodge W100. I will be helping him put it back together, along with a few friends, this spring. However, I've never worked on a project like this one and need some basic beginner advice. Also notable is that he bought the truck in pieces, so no one working on it has seen it assembled. My questions are below:

- What order should we tackle the project? (For example, do we assemble the body first, or install the engine & transmission first?) Is there a "step by step"?

- What resources should we have at our disposal?

- Is there a book along the lines of "Frame Up Restoration for Dummies" that would assist with questions like the first one that you'd recommend?

Thanks!

[Ron in Indiana]

First to what extent is the truck disassembled? The frame is bare meaning no drivetrain or body? I'll assume the axles are still on the frame so to make things easier to get to I'd put the engine and transmission in first. Then the cab can be set on the frame followed by the front fenders,core support, hood etc. The bed can be the last to set on the frame. I've done several ground up restorations and have a 58 W 100 in my shop right now. A factory service manual would be a good thing to have. They are on ebay all the time. This will answer mechanical questions and give a wiring diagram. These aren't difficult to put back together but there are some quirks you'll need to know. The steering column and steering box are one unit and must be installed as the cab is set in place. There are small half moon parts in the clutch bellcrank shaft that MUST be installed. I should have precluded this with asking if any clean up and painting are planned? If so you want to do the frame, bottom of cab and drive train before assembly. Any bodywork to the cab is easier with the cab off too. The cab mounts in the front of the floor are known to rust out. This has to be hand fabricated and is best done off the frame. Just take your time and if you get stuck just ask, the only dumb question is the one not asked. One more thing where will the truck be located during reassembly. It may be that someone here is close enough to you to come by and guide your work. Good luck and have fun. Ron

[arcking]

I wish I had some pics to post, but seeing as I don't at this point words will have to suffice. The currently, the frame is 'rolling' and has suspension and axles mounted, but that's pretty much it (I believe the T-case is mounted as well). The frame and axles have been painted, the engine was painted but needs to be repainted, all body work has been done, and everything else has been primed.

Thanks for the tips. The project is a bit overwhelming, but after years of no progress being made it's time to tackle it!

We'll be working on it about an hour north of Pittsburgh, PA. Are you aware of anyone in the Western Pennsylvania area?

[Ron in Indiana]

It sounds like most projects of this type, good intentions derailed by life's events. A roller is a good place to start. Paint the parts that need it before you install them. Paint the bottom of the cab and firewall if not the whole cab too. If it's this far a little more prep work will be worth it in the end. The cab can be painted after assembly to avoid scratches now. As I said I've done several of these and can help you along. The only Power Giant friend I know in PA close enough lives in Manhiem.PA. You can email me pictures direct when you get them or have questions. I hope all the bolts came with the truck since most if not all are fine thread. Have your buddy get a service manual on ebay just do a search for 58 Dodge truck. My address is 59redtruck(at)frontier.com remove the AT of course. I have aided several others with their projects. It may seem overwhelming but if you break it down into sub assemblies you'll soon see progress. It's a little like eating an elephant, just take a bite at a time LOL.

[arcking]

Thanks for all the advice! I'll be sure to let you know how it goes - I'm sure there will be lots of questions along the way! Never taken anything like this on before.

One of the first steps is going to be getting all the parts out of the boxes. I'm pretty sure he's got a service manual, so we're set in that regard.

Does your friend in Manheim have any similar trucks similar to the one I'll be working at this time? There's a good chance I'll be out that way in the next week or so and having a look at one (and taking some pictures) would be a great help.

[Ron in Indiana]

Taking inventory and marking the boxes will speed things up in the process. Leon has a 59 W100 which is similar to the 58 but has mechanical differences such as hanging pedals and firewall mounted master cylinders. Body difference s are the grill and no running boards but that's minor to what you are working with. Send me an email so I can forward your address to Leon. He's a great guy and I'm sure he'll help as much as he can. We're all in this together like family, I just ask that you help the next guy who comes along. I'll look for you email. Include your name please it's a little more personal that way.

[arcking]

Any suggestions for what categories/boxes we should start with for the sorting? (Or better yet, how to tell what should go in each box!)

[Ron in Indiana]

You are at a disadvantage of not knowing what goes together. Interior parts should be easy enough. Engine/ drivetrain should be also. Beyond that not knowing how far down it was taken in the first place it's hard to tell you. Is the bed apart as well? There are bed strips and a lot of bolts for that along with cross members. Try this, arrange what you think goes together and the parts you question for location or identity. Take pictures of these and send them to me and I'll identify them. Try not to bunch or get to many so you get a good close shot. One more, do you know if the brakes were overhauled? Parts are available at Napa or Autozone like most mechanical parts for these trucks. Rubber parts like the windshield and back glass are out there too along with window channels and the like. Is this a big back window or small back window cab? It's easy to tell since the big window is a wrap around. Just got your email I'll catch you there

[arcking]

I'll give it a shot and see how far I get. I really appreciate your willingness to assist! I can't recall what size rear window it has. The bed is completely disassembled.

I do not know if the brakes were overhauled - what does that involve? New shoes, springs and cylinders? From some research I did a while ago, I think the rear axle is a Dana 60 or 70 - not sure if that'd be stock or not. However, it appeared that you had to remove the axle shaft in order to remove the drum and get at the brakes.

[Ron in Indiana]

What's needed for the brakes depends on the condition they are in now. New wheel cylinders are best to go with a complete brake job. Turning the drums, new shoes , hoses etc add up but it's relatively easy to do. IF you have an original axle it will be a 6 lug corporate axle with a single nut in the center. This is the axle nut holding the drum and hub on a tapered shaft. These can be a real pain to remove and can only be done with a PROPER three leg puller. The front axle is a Dana 44 and it's pretty straight forward. Again service manual comes into play here. I don't know your skill level or experience so bear with me if I over simplify sometimes. If you indeed have a Dana in the rear it's a full floating axle and again easy to work on. The good part in all of this is that you can check the brakes now more or less with the MC on the frame. The brakes are NOT self adjusting so you have to do this manually through the backing plates. Since this has been sitting for sometime I'm sure the lines will need to be bled before adjusting the shoes. The rubber hoses on the front and rear may look in good shape but they can clog to the point of not letting any brake fluid through, been there done that. And on and on it goes haha.

[arcking]

The rear axle looks something like this (NOT a shot from the truck):

based on what you described, it's not the original axle. I'll have to check the drums and brake parts once I get things apart. There are no brake lines on the truck at this point, so all of that will be new.

Just assume I have no idea what I'm doing - I've been tinkering with an '87 Toyota Pickup in an attempt to learn, but I'm very much a novice still.

[Ron in Indiana]

Ok let's back up a little. Maybe you have 59 W100 which would have an eight bolt Dana 60 rear axle. Does the front axle have 8 lugs? If the brake master cylinder isn't on the frame that would tell me it's a 59. Are there running board brackets rivited to the frame? 59's didn't have these. I know you aren't near the truck but this will help a lot in knowing exactly what year truck your friend has. The 58 service manual goes along with a smaller 59 book for a 59 truck. Also if there are no holes in the cab floor for pedals and it has hanging pedals then it's a 59. The dash is different also, the glove box is on the right side in a 59 and centered on a 58. This could make a BIG difference. I like 59's but I'm biased, a little haha.

[arcking]

I will have to get back to you on that - it's entirely possible though.

[arcking]

Here are some more details from the seller my friend purchased the truck from:
Engine: 360
Transmission: 4spd, low 1st
Transfer Case: NP205
Front Axle: Dana 60
Rear Axle: Dana 70

Here's a pic from the previous owner showing the truck assembled:


Here are a couple of the truck as it is currently:

[arcking]

And one of the interior of the cab as it was referenced previously: