Our continuing Project F-1 truck is moving right along, and this month we tackle installing the glass in both the cab and the doors. Once again, Altered Engineering in Orange, California, got the call as we continue to build this custom hauler. All the original glass in the '50 Ford had seen better days, so we called on Sacramento Vintage Ford for all-new glass. A few days later the big brown truck arrived with several boxes.
The replacement windshield was ordered with a tinted strip at the top for sun protection on those bright So Cal days, while the door and back glass were smoked for privacy and a cool look. To carry the smooth look that the truck was getting even further, Sacramento Vintage Ford supplied a one-piece side-glass kit that eliminates the vent windows in the doors for a totally clean and custom look.
Since the guys were installing new door glass, we figured that they might as well be power, and this also seemed like a good time to install solenoids for the doors. The outer handles have been shaved from the body, so we needed a way to open them from the outside. AutoLoc came through with the power window kit and the solenoids, as well as some very cool power window switches that will actually allow us to keep the original-style replacement window cranks from Blue Oval Truck Parts.
Many backyard builders are afraid to tackle glass installation and leave it to the pros. As the following pictures show, it really isn't an impossible task--especially in trucks like the F-1s that have all flat glass, not the curved windshield as on the '53 and later Fords.
We took the better part of a day to complete the job, but with some patience and a little luck the home builder could duplicate these results over a weekend in the garage with a couple of buddies. Check out how we installed the glass and hardware--then you'll have an idea if you have the tools and ability to tackle this task yourself.
Don and Peter tackled the...
Don and Peter tackled the one-piece side windows as the opening task. There's a brace welded to the door for the vent window divider bar that has to be removed first. They taped the door to protect the paint, and then Peter started to remove the offending brace with an air-powered die-grinder and cut-off wheel.
The brace was cut out with...
The brace was cut out with a die-grinder and cut-off wheel. Peter was making sure that the cut was flush with the door skin so the window felts will fit properly.
The Sacramento Vintage Ford...
The Sacramento Vintage Ford one-piece window channel was slipped into the door for a trial fit. It may be necessary to trim to fit exactly in your door. These old trucks were not built with the close-tolerance precision as a modern vehicle.
After the fit and position...
After the fit and position of the one-piece channel was approved, glue was applied to the backside of the channel. Next, it was taped in position while the glue dried
With some tape on the edge...
With some tape on the edge of the door for protection, Peter slipped the one-piece window glass into the door. You can see that the lower track that controls window operation comes attached to the glass from Sacramento Vintage Ford. The window goes into the door sideways and then is rotated into the correct position.
These universal kits from...
These universal kits from AutoLoc were used to turn the hand-crank windows into power operation. These will work great on any flat-glass application and weren't very difficult to install.
It's necessary to get a height...
It's necessary to get a height measurement before mounting the power window unit to fit your specific truck. You need to make sure that the window will go all the way up and that it's resting on the stop when all the way open. A little patience and trial and error was necessary to figure out the mounting location.
To control the power windows,...
To control the power windows, AutoLoc has these cool power window switches that allow you to retain your original window cranks for a stock look. The window crank will move approximately 15 degrees up or down to open and close the window.
Here's the new replacement...
Here's the new replacement window cranks and inside door handles from Blue Oval Truck Parts. From the inside the truck keeps an original feel while controlling modern conveniences. Even though we're installing AutoLoc solenoids for the doors, we kept the mechanical inside door latches and handles for safety sake. You wouldn't want to be trapped inside the truck if the battery went dead or when/if an electrical short might occur.
To run the wires to the doors...
To run the wires to the doors for both the power windows and the door solenoids, we found these trick billet aluminum and stainless steel flexible wire conduits from Specialty Power Windows. The spring moves in and out with the door, preventing the wires from being pinched and also offer a very clean look when the door is open.
After making sure that the...
After making sure that the spring, collars, and wire cleared everything inside the door, Don used a hole saw and drilled the appropriate holes in both the door and the doorjamb.
The aluminum collar was slipped...
The aluminum collar was slipped into the doorjamb with the spring attached. The spring stays attached to one side and slides in and out of the opposite side. We chose the doorjamb side to be stationary to make sure that the spring wouldn't get caught on anything behind the kick panel. They can be installed either way depending upon your individual application.
The other side of the spring...
The other side of the spring was then flexed into the collar in the door to complete the installation.
As you can see with the spring...
As you can see with the spring in place, a very clean look is achieved without wires dangling or being pinched and shorting something out. The other nice thing about this method of running the wires is the accessories continue to work when the doors are open, unlike the "contact-type" plates that do not operate when open.
This is the stock door latch...
This is the stock door latch assembly out of the F-1. After the guys cleaned it up and lubed it for another 50 years of service, they attached the small cable that will be controlled by the solenoid to open the latch.
Here, the solenoid from AutoLoc...
Here, the solenoid from AutoLoc was being located for a direct pull on the cable to open the door. We wanted to make sure that the cable had a direct pull so that it won't bind. It made for a smooth operation.
Four holes were drilled to...
Four holes were drilled to locate the solenoid. These solenoids have quite a strong pull and need to be securely mounted to the door.
Peter now mounts the solenoid...
Peter now mounts the solenoid inside the door using the supplied hardware.
The cable was then fed through...
The cable was then fed through the solenoid and secured by crimping the ferrule that will keep the cable from slipping during the pull of the solenoid.
Because these solenoids pull...
Because these solenoids pull a lot of current, a relay was used for electrical safety. By mounting the relay close to the solenoid, the large current doesn't have to travel very far--eliminating the potential for overheating the wiring or blowing a fuse. The remainder of the wiring and the transmitter were hidden in the kick panels. Now with just the push of the key fob controller, the doors will open like magic.
Moving on to the remainder...
Moving on to the remainder of the glass, Peter installs the Steele Rubber Products weatherstrip to back window (shown) and the windshield. These replacement weatherstrips are an exact reproduction and fit great.
Here Don was pulling the string...
Here Don was pulling the string that he installed in the groove of the rubber and slipped the weatherstrip into the opening. With a little soapy water applied to the rubber and a slow, even pull, the windshield installed easily.
With a little pressure from...
With a little pressure from the outside, the windshield popped fully into place.
From the inside you can see...
From the inside you can see how the rubber conforms to the shape of the window opening and fits like a glove.
From the outside, the glass...
From the outside, the glass and rubber also fit the truck perfectly for a leak-proof installation.
With all the glass and new...
With all the glass and new weatherstrips installed, the F-1 is looking more complete everyday. The one-piece windows clean-up the look of the doors considerably. They complement the shaved door handles. The smoked glass and tinted windshield not only look good but will also help keep the cab cooler on those hot summer crusin' days.