Several of my best adolescent car/ truck memories involve first rides: one was in my cousin's shortened-exhaust four-banger Model A Sedan. The interior was stripped down to bare chicken wire. It was loud and drafty, but a most exciting experience for a pre-teen looking forward to the driving privilege. Another neat ride was in an Oklahoma farm truck that was a "patina truck" 50 years before the term was invented. Also drafty and well worn--the experience of riding with my uncle in the high cab is still a vivid memory. The rattles and creaks and smell the fresh-cut alfalfa as we drove to town were as exciting as a picnic shared with kissin' cousins.
When I rescued my basket-case '40 Ford pickup, that distant farm truck ride with my uncle visited me like a ghost. Restoring the desert derelict would be a nifty reminder of a time when excitement was as uncomplicated as a vacation ride to town in an ancient work truck. This project's journey has largely moved along at a snail's pace. Several extended dead-end excursions at hot rod shops did nothing more than delay progress. On the other hand, the experience of seeing Art Barker's crafty restoration of the rusted and wrinkled cab was a special one ("Saving Private Henry," CCT, Jul., Aug. '04).
Another special experience occurred recently as I watched the experienced chassis-building crew at Total Cost Involved build a new chassis for my '40 Ford pickup. Perhaps you can relate to achieving a goal set years ago. The original chassis had a bent framerail and the engine mounts were positioned too far forward. Several other space/location problems needed to be resolved--these were going to be expensive as well. We plan to drive this truck anywhere and everywhere; thus a solid foundation will provide the confidence and reliability to do just that.
The chassis construction began early on the morning of May 17 at TCI. We photographed each step of the construction much like a proud dad videotaping a birth. At each station the crew performed their tasks with confidence and precision. By mid-afternoon the frame and crossmembers were assembled and the brake lines were plumbed. The following week the suspension was assembled and the chassis was a roller.
You may remember, last year CCT covered the development of a new Ford F-1 chassis from TCI in our Mar., Apr., and Jun. issues. We also featured the powdercoated chassis prominently in the October '04 issue as Altered Engineering was beginning the pickup's body panel assembly. Needless to say, the new F-1 TCI chassis was a big hit with vintage '48-52 Ford pickup owners.For those of you who wish to see the improvements and the assembly process of a modern reproduction chassis, follow our photo essay. Then, if you're still pondering the merits of purchasing one, consider how much satisfaction you might have knowing your vehicle will survive another 50 to 60 years.
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 Each new TCI chassis begins...  Each new TCI chassis begins life on the frame- rail jig, where long strips of steel are welded together in 5-inch short welds to prevent warping. |
 If you look closely you can...  If you look closely you can see the 4- to 5-inch welds were spaced equidistantly apart. They were filled-in after a cooling period. |
 After the edge-welding was...  After the edge-welding was complete, the framerail went to the grinding room where the welds were ground smooth. Good weld-penetration is important for a clean framerail. |
 We arrived at TCI as our framerails...  We arrived at TCI as our framerails were located in the '40 Ford chassis jig. A three-man crew began to install the rectangular-tube crossmembers and the front crossmember for the independent front suspension. |
 Jorge Tejada prepared to...  Jorge Tejada prepared to clamp the forward leaf-spring bracket in place. |
 Jorge checked the measurement...  Jorge checked the measurement on the bottom of the framerail for proper positioning of the leaf-spring mounting bracket from the rear shock-absorber mount crossmember. |
 Meanwhile, Chuy Rodarte prepared...  Meanwhile, Chuy Rodarte prepared to install the front crossmember. |
 Each dimension was double-checked...  Each dimension was double-checked before and after each subcomponent was tack-welded in place. This is best achieved by cross-measuring the chassis diagonally. |
 It's possible for the crossmember,...  It's possible for the crossmember, or bracket, to move slightly when being tack-welded. |
 Only after Chuy was satisfied...  Only after Chuy was satisfied the position of the front crossmember, or bracket, was correct, he then welded the piece securely in place. |
 The upper shock mount is located...  The upper shock mount is located on a crossmember slightly behind the rear axle. The crossmember has steel sleeves welded into the square-tube crossmember. Here the sleeves were being ground smooth. |
 As work progresses, Jose Portillo...  As work progresses, Jose Portillo began to install the ladder-style X-member of the chassis. |
 The double rectangular tubing...  The double rectangular tubing that makes up the center X-member creates excellent strength and allows room to position the exhaust between the X-members. This will reduce the risk of damage to the exhaust system, even if the vehicle stance is very low. |
 The brake-booster bracket...  The brake-booster bracket is located in a protected area below the driver-side floorboard. |
 At this point the crossmember...  At this point the crossmember had been completely welded, and it was time to remove the chassis from the chassis jig. |
 The crossmember welds were...  The crossmember welds were ground smooth and inspected for penetration. Soon it would move to the next station where the engine/ trans mounts would be installed. |
 The clock indicates 10:30...  The clock indicates 10:30 and the first crew is finished with their tasks. |
 Jorge, Chuy, and Jose have...  Jorge, Chuy, and Jose have proudly completed their portion of the new chassis construction. |
 A Ford 351W engine and Ford...  A Ford 351W engine and Ford AOD trans would be the front part of the drivetrain. The next crew selected a dummy block and trans housing to accurately install the engine/trans mounts. |
 A special jig was located...  A special jig was located at the front of the framerails. Dimensions were taken from this fixture. |
 The engine would need room...  The engine would need room up front for a water pump, a fan, and pulleys. |
 The crew checked the centerline...  The crew checked the centerline of the AOD trans housing and engine, as well as the correct position forward/rearward. |
 It's also important to mount...  It's also important to mount the engine/trans on a slight angle to position the driveshaft with the proper offsets. This eliminates the possibility of vibrations created by too much offset in the driveshaft/trans universal joint. |