Archive for July, 2019


Operation RESTORING BROWN Part III: An Electric Interlude

Jul 26, 2019 in vantruck

Its time for another installment of “Charles’s Moving Bondo-Castle”!

You might think the worst of it was performing the roof rail welding, but really this thing is far far from the “Point of Maximum Entropy” where your project is the most taken-apart and hopelessly scrambled possible. It would be a waste to just spraybomb over the welds and shove it all back together now, so with most of the exterior Bondo Castle building wrapping up, and with the interior taken apart, I needed to dive even deeper into the loosely-bound fiberglass chasm to remedy the demons that haunt Vantruck called “Aftermarket RV company wiring”.

There are few horrors on this beautiful Earth which approach the level of cocaine-addled depravity that is a 1980s RV builder trying to put lights together.

Past episodes index so far:

  1. Episode 1 – the initial teardown of the house of horrors
  2. Episode 2 – Welding and repairing the major roof seam holes

Let’s begin! Before anything else, there was more discovery to be done with the wiring.

Full disclaimer: A lot of these photos are put together as a narrative. Often times, while doing bodywork, I’m waiting for something to dry or cure before I can move on, and in that hold-state, I work on something else. In reality,  you see, these electronics operations were interleaved with sanding something or primering over something. I decided it was more clear to keep them separate events – as if I did a whole day only grinding old paint, then another whole day or so only doing wiring.  If you’re detail oriented, you might notice some things which are slightly out of order in the background!


I’ve never trusted the side handles on this thing enough to actually want to hang onto them for anything. That’s because I figured it was, like everything else, just put together with two #8 self-drilling sheet metal screws. But to prepare the cab for painting, they had to finally come off anyway.

The funny thing is, I’ve actually been here before. I previously used a small right-angle screwdriver-bit ratchet to get at the “Courtesy Lights” (as I now know what they’re called…. remember, they’re labeled “Hi I am a Van” Lights in my book) behind the handles.

Well now that I unsnap the decorative trim, I can see that they went to the effort of putting a rivet nut into the sheet metal. Wow, such high production value. It’s still thin body shell steel, but at least it’s a fully threaded 1/4-20 bolt!

My pleasant surprise was short-lived as I then discovered the Van Lights were “installed-in-place” . They ran the damn wire through a hole in the body and then added the light. It means I’d have to cut this off and start over later. Sigh, my disappointment curve takes another downward inflection.

The backing plate for the light was a chromed over piece of steel, but both were substantially rusted. I may just do the same treatment here as I did to the body steel, since it’s not like they do much useful reflecting – just rust conversion treatment, then primer, then maybe whatever Silver Metallic spraypaint is on the shelf.


Next up, I moved onto chopping off the “I am a over-80-inch-wide truck” DOT cab marker lights. I knew these held substantial rust underneath, and I ordered replacements since the lenses were all crazed and cloudy anyway.

With no interest in keeping these in good shape, I literally sliced through everything with the big 3D printer bed-scraping Instant Amputator 9000. I love these things, and own several – they do everything in my shop domain from opening packages to whizzing off stickers from surfaces to occasionally dividing up pizzas.

Yikes. I went through at some point last year and treated these areas, so they hadn’t grown much worse, but I definitely had to do something here.  Maybe a Most Correct Possible restoration will still cut out and replace this area, but I was just going to once again clean it up and Bondo Castle over it.


Wherever there was bubbled paint, I mass-erased it with a coarse flappy wheel, then “primed” the surface with a small amount of painted-on fiberglass resin, then laid out a layer of hairy Bondo.

I suppose it’s more of a Bondo Lawn. For durability, I purposefully left it a millimeter or so higher than the surrounding landscape post-sanding.

Same operation on the back. There used to be roof rails here at some point, beginning behind the visor and ending at the “endcap”, but they were removed many moons prior to me. I’d plugged the four holes with various forms of rubber stoppers, and I’ll do that again once things are cleaned up.

This is what the totality of the operation looks like, more or less. I was in the middle of addressing the airhorn fitting here. As the sections are cleaned up, I blast some primer over them.

Centurion’s MO with attaching anything was just fill the whole thing up with silicone  sealant and call it good. This probably works fine right up until the sealant dries up and cracks with age!

The airhorn is a Sparton branded one which seems to have some kind of standard fitting for that era – a single bolt front mount, and a combined rear air fitting plus mounting stud that I of course broke off the moment I tried to remove it. I ended up locating several similar ones on eBay, and ended up buying an identical-looking model.

For now, it’ll just get cleaned up and primered over like all of the other holes in the roof.

Moving on with fitting disassembly, this is the combined CB/FM antenna it came with. The CB part appears to be broken somewhere, and the FM part has never really worked. When I tried to unwind the nut, of course the whole thing just exploded on me. I had no particular desire to save this part, so ended up using a lot more force and just cranking the thing apart.

Of course, I dunno if the antenna wire was already broken/damaged or if I just blew it up completely. No matter, since I’m just going to plug this hole first and foremost.

There is a CB radio splitter device hidden under the dashboard which this cable runs to, via a wire grommet under the passenger side dashboard (it exits screen right and turns under). From there, it fans out to the head unit area as a standard FM antenna fitting, and the other branch was actually pulled up the A-pillar and ran to the console CB radio. There’s no reason for me to suspect that the latter two cables are bad, so I will be leaving them in place. In the undefined future, I’ll probably return to this and replace it with a modern NMO mounted antenna.


Having now traced all the wires I care to, I began the task of poking things with a multimeter and seeing what wires were hot or cold in what key positions, and back-tracing the remnants of the interior lighting wires and labelling them. My goal was to combine the original mess into two connectors – one inbound, providing vehicle power and dashboard buttons, and one outbound that sent this power to the lights and other hungry implements.

The overhead console got the complementary treatment. It was relatively easy to see what led where, so I focused more on integrating better wiring practices and replacing cheesy wiring jobs.

I had one rule going into this electrical refit:





I hate those things. Also called “quick splices” or similar, they just loosen up and corrode over time, and look like shit. They practically encourage shitty wiring practice, and one power line I yanked out had no less than four leeching off it.

A short evening of work and here it is.  It’s not well constrained, but just organized.

I also decided while doing this that the CB radio microphone will be hung on the console itself. Centurion made the questionable (hah) decision of routing a DIN microphone extension cable from the console, across the roof, down the A-pillar, then up under the dashboard to the meet the microphone which already has a 3 foot long springy-cord and whose mounting points I can’t even find any more.

Much of my time spent driving this thing is in fact trying to keep the microphone from being tangled in the steering wheel. So I was going to strip all of that out and just have the short cord dangle on a “button” style mic hanger.

As I had zero intention of actually hooking up the antenna now, the CB radio will, remain a visual fixture to complete the 80s-retromod aesthetic.

After doing both ends with the highest-value connectors this thing will ever experience (MetriPack-150 series connectors used in all of my megawatt-scale vaping rigs at the company!), I clicked everything together to make sure everything still worked and I didn’t, in fact, wire the starter to one of these.

Next up was a tuck and clean on the harness itself.

At this point, I was beginning to get lighting products in the mail. First up are the Truck-Lite model 25 “I am a giant-ass truck” lights. I ordered five, of course, not realizing each order was for two. So now I have enough for Mikuvan also! Say, is it illegal to wear “I am a giant-ass truck” lights if you are not one?!

However, far more interesting in terms of lighting was the…

Miku Blue and Miku Magenta LED strips I found on eBay. Short of RGB mixing, the color I substitute for Miku Blue is generally marketed as “Ice Blue” which appears physically to be white LEDs with phosphors that really skew their color temperature towards blue. Like taking a cool-white LED and making it even cooler (or, I suppose, “hotter” from a physics perspective).

I had no agenda for these reels, actually. They were found in my quest for other forms of LED lighting. I bought enough to make full-length underglows on the side steps (of course), but they are not weatherproof so I’d need to enclose them in a LED strip channel extrusion first or something.

Whatever. Something even MORE cool came in the mail too!

This is another happy accident while I was investigating RGBW 5-pin LED strips. It’s a Chinesium ‘touchscreen’ controller, by which they mean ‘touch sensitive colorful pictures’. The reason I found this was because I was specifically looking for NOT wireless/IR remote types, instead focusing on wired controllers.  The IR kind is by far the most commoditized, but I didn’t like the idea of a remote hanging around inside since that’s what’s in there now, and I always drop it.

Let’s take a quick look inside!

There must have been some kind of miscommunication or severe competency shortage in the design department, because it’s got no mounting features anywhere on the backside . Instead, you have to carefully pry it open being mindful of the tiny ribbon cable that connects the touch buttons to the main body. It’s literally in the instructions to use a tiny screwdriver to push the ribbon cable latches out before separating the halves.

If you don’t read that far in the manual, or you apply just too much force, you’ll rip the ribbon cable or connector right off. I do wonder how many of these have actually been installed by real people in something.

Oh, it gets even better. After you install it using the hidden mounting holes, then you get to somehow maneuver the tiny ribbon cable back into the connector and use a tiny poker tool to re-seat the latch. This is all officially sanctioned in the instructions. I managed to execute it with my surface mount device handling tweezers. Both of them. At once.

Yeah, no. It’s getting a piece of Dual-Lock gender-neutral justice Velcro slammed right on the housing. No elegance from me whenever I actually decide to implement it!

The gear inside is otherwise a generic 4-channel RGB+W controller. Common anode, four pull-me-down low-side FETs.

It definitely Doesn’t Not Work, so if you can stand the absolutely nonsensical mounting needs, I do recommend playing with one. The color wheel really only has 16 or so positions, not that your LED strips have enough current-to-color mapping calibration precision to duplicate it.

I only have one complaint here for the physical UI, which is it’s too easy to fat-finger a color as you turn it on and off, so it often wakes up in the Brown position. I didn’t even know LEDs could emit brown light, but here we are in 2019.

Alright! Back to work. I created a secondary harness specifically for the roof cabin lights and five cab lights. These were all previously ad-hoc wired with vampire clips. I separated them into their own bus with only one connection to the feeder wire coming out of the roof harness.

I also went ahead and routed a length of 5-pin RGBW LED strip cable the full length of the cab to the former exit spot of the Sex Lights. So not only do I have an on/off supply-level connection for the not-yet-designed (but which will be GLORIOUS) Next Generation Sex Lights™, but the option of using this RGBW controller up front if needed.

It’s fished through the same wiring run as the other interior roof lights – see the displaced fiberglass batting to the right. That gets re-secured over the wiring run once I decide I’m satisfied.

Oh, yeah – all of the lights that are going back in received “real” connectors that I can in theory reconnect and disconnect – if I do come back in here, it’ll be possible without wanting to level entire cities as retribution.


And the front roof wiring is finished – the (not yet replaced/cut off) “van lights”, cab light connections, and interior roof lamps all work. At this point, I’ve basically done everything I care to in terms of wiring rehabilitation and could have put the interior panels back together. I decided to leave that exercise until after the painting process just in case I thought of some other intelligent modification or change I wanted to make.


Third Brake Light & Bed Light Mod


Speaking of which! Here’s another quick diversion from the main project besides laying the foundation to add tasteless LED strips to everything. So one of my long time low-level peeves has been the “Leave this light on to accidentally drain your battery” light, also known as a bed light or cargo light.

There’s just so much of everything  on Vantruck, so much bulk and space-occupying visual styling, so much dual-wheel enabled highway manspreading. Then you get to the back of the cab and there’s this teeny little bed light.

It’s like those Greco-Roman styled Renaissance statues of extremely chiseled men with microscopic penises.  Not only was this thing extremely puny and dim, having only a type 194 socket bulb inside, but the attachment was just two drywall-esque construction screws into the ~3mm thick fiberglass van endcap. Meaning? It’s always been stripped. Every screw I try to use in here strips. I drilled the holes out a long time ago for the next size of drywall-esque screw that’s larger, and that held on for a while before that also just stripped out.

It’s really only been hanging on by the grace of Robot Jesus.

As one of the last things I can do before I’m just flat out of excuses for painting, I decided to do some customization here. In keeping with the general “hello for i am giant truck abomination” aesthetic, I’ve been buying samples of various semi truck and commercial truck lighting products off the likes of Iowa80, Raneys, and random eBay and Amazon searches for the same. My goal with this add-on was to make this assembly huge and obtrusive like the entire vantruck – I wasn’t about to buy some puny plastic Jeff Bezos Special here. I used custom semi truck taillight housings and trailer light bars as a mental guide.

An additional desire of mine was the ability to add a center brake light. I’m not a fan of the North American-specific combined turn signal and brake lights, especially prevalent on trucks here, since it can often be ambiguous if you’re turning or stopping or both.  Light trucks weren’t required to have center brake lights until 1994 in the US, so this would be a wire I’d have to run from the brake lighting circuit.


The foundation of the new bed light will be these triple trailer light brackets which accept a 6″ oval light that’s a standard size in the industry. You can get them either in old school incandescent or obnoxiously get-off-my-lawn bright LED! Guess which one I sprung for. Let’s say “bigger than in the picture” was my thought after getting these in and unboxed, despite the dimensions being clearly written in the item description.

Robots are always bigger in real life than in CAD, and to my chagrin and future degenerative eye disorders, circuit boards are always SMALLER.

Why did I get two? Well, they’re tail lights for your trailer, so they come in pairs, duh. This just means I can either have a backup or give one to Mikuvan too.

Quick in-place mockup to make sure it will definitely fit  and looks the way I think it will.  “Looks bigger in real life than in the product photo” often just leads to “Looks reasonably sized if not a bit smaller than expected” once the reference coordinate system changes, namely once placed next to Vantruck.

Hmm. Maybe I should have sprung for the 4″ round housing brackets.

TECHNOLOGY SPREAD TIME! I designed this 27″ wide spacer body in Autodesk Inventor to the profile of the stainless steel bracket, added mounting hole locations, and then split it into three dovetailed parts. They were knocked out on my Markfrog gallery and then epoxied together.

I decided to make this spacer instead of cutting a long slot into the van endcap to install the lights flush-style. It’s in my interest to modify and cut up the van endcap as little as I have to, I decided, since that’s not a part I can really replace. If I make any changes in the future, I’d have to patch over a 2 foot wide slot, the cutting of which would also introduce other unknown/don’t-wanna-known structural issues to that area.

Installing this setup with the spacer body would only necessitate drilling a few small holes. It might look just a little weirder than what I consider to be a smooth flush mounted setup.


The attachment method I decided to use here is known as a “well nut”, a rubber rivet nut, or as I’ll probably call it from now on, a wubbie-nut. They work like real rivet nuts, except you just tighten the fastening screw and the molded insert nut squishes out the rubber behind the panel being fastened. It’s a compliant, sealing, electrically insulating, and reversible method of attaching relatively light stuff to sheet metal. Since the fiberglass van cap is really only like 2.5 to 3mm thick, it won’t hold a thread at all, nor did I want to use any permanently installed rivet nuts or inserts.

This is what the assembly will look like. I actually don’t think it looks as off as I was anticipating.

The spacer body also allows all the wiring and connections to be done outside the endcap, so I only have to find space for three wires to exit the endcap at the location of the original bed light.

To make the brake light do what I want it to do, I had to tap the circuit upstream of where the brake light switch (which feeds power to the circuit when the pedal is depressed slightly) is connected to the turn signal interrupter (the blinky thing) since that’s where it splits up to the left and right sides. It turns out this wire was already tapped for the trailer brake controller, and I just had to do a bit of digging to locate the UGH, ANOTHER VAMPIRE CLIP they used to link up to said trailer brake controller.

I got peeved at the vampire clip, so I then spent an hour rewiring this area. My bonus brake light circuit got a proper twist and solder splice to this circuit, and I got rid of some more redundant wire, then wrapped the whole thing and constrained it. This photo is pretty much looking directly upwards from the driver floor.

So now we arrive at the week of July 4th, and I’ve exhausted almost everything I can do that’s not beginning to paint the damn thing. I’d seen this moment coming, and pregamed order a few samples of automotive paint systems and watching some videos on how to do it.

As usual, I’m about to try it in a way that is utterly moronic and advised against by pretty much everyone with actual knowledge of the subject matter, but since it’s just me fucking around in public and writing about it, the entertainment value takes precedence.

Welcome to the paintening.

Operation RESTORING BROWN: Romance of the Rusty Roof Rail Repair

Jul 05, 2019 in vantruck

Alright, here we go! The first meat and first potato of Operation RESTORING BROWN, the only thing which I technically set out to do and could in fact just rattlecan the whole thing brown right afterwards and be done with it. I’m going to keep an rolling index of previous posts here so by the end, everyone can read the whole thing and realize just how embarrassing it all was. We begin of course with…

  1. Episode 1 – the initial teardown of the house of horrors

So, I’ve established that there wasn’t really anything too flammable in contact with the inside of the roof where I’d be making repairs, which means it will go pretty quickly once all the prep work is done. What is it exactly that I have to put back together? This:

Yikes. These spots were already present when I bought Vantruck in late 2016, but they were smaller in visual magnitude because I hadn’t explored them until maybe last year. By then, the two ends were “joining” in the middle causing the rust-colored stain in the roof paint in that area, and I spent a little whole doing some initial scratch-n-sniff with pulling up degenerated sealant beads and hitting the area with a wire brush. I also covered the area in rust converter (causing the dark color) and gave it a blast of clearcoat paint, which was able to preserve it until now.

There’s a little divot all the way to the right near the “van seam”, which was where I applied a grinding wheel to try and get a sense of how the roof was attached. I had done some research then on how I would make this repair, and feared the worst.

You see, Ford in all its wisdom decided that the best way to make a roof drip rail is to also use it as the rolled spot weld seam (pinch weld) to attach the roof to the side panels.  The spot welds are then coated with a bead of body sealant. Predictably, the sealant deteriorates and lets water into the crevices of the spot welds, upon which it rusts out and there is scant little you can do about it except some very expensive metal replacement therapies with harvested body panels (if you’re lucky to find one since they all rust in the same place!). If you just run an image search for “Ford drip rail rust” you can see many examples of this failure mode.  What I now fear is Mikuvan’s drip rails are made the same way, as it seems to be a popular method of making the roof panel back then. It doesn’t have any issues there, but it’s only a matter of time.

For me right now, it meant having to cut the entire section out and then…. not replace it with anything. My restoration, my rules – I was just going to cut the damaged sections out, bridge the gap with welded on strips, and just reseal the remaining. It’s going to be visible, ugly, and purposeful.

But before I could begin anything, I had to peel back the walls of the house of horrors even more, since the rust extended under the….

van seam. This was a rather cringeworthy and frustrating exercise. Frustrating, because I had to impact-drive out around 25 time-cured Phillips-head self-tapping sheet metal screws. Cringeworthy because really? Just driving irregularly spaced flat-head screws into stuff?

This aluminum trim strip originally had a large rubber seal clipped over it. The rubber seal deteriorated and crumbled away slowly, so I removed all of it about the same time last year I tried to arrest the roof rust.

I only managed to destroy 2 screws while removing the upper half of the trim strip, which I had to drill out and grind away the remnants thereof. Honestly, I was expecting so much worse. What’s going to happen here is eventually I’ll remove the whole van seam trim strip and refinish the underside separately. They just screwed it on and painted over it, which means the underside has a lot of surface rust and built-up grunge.

Bonus points if you can spot the red Sharpie line they marked and followed to cut the van!  Yes, there is an actual red sharpie line on both sides.

We begin the actual demolition now, where I just arm up a cutoff wheel into a grinder and zip the remains of the drip rail off.

Quick note – just because I found “nothing flammable” on the inside of the roof, doesn’t mean I didn’t keep a fire extinguisher and a pressurized plant sprayer bottle full of water nearby. The interior was still questionably fire-resistant 1980s urethane foam, cloth, plywood, and carpet. This cutting operation created a lot of sparks, and I’m sure there will be even more to come.

Following up with the cutoff wheel, I used a flappy wheel to remove the paint in the area and explore how deep the rust pitting went i.e. what can still be reasonably salvaged. I’m not planning on removing every semblance of rust, especially as much of it has been hit with the conversion compound and should in the end be painted over.

It was time to arm up my limeboi here with a proper cart and C25 gas bottle. This is what you were designed for!

A long time ago, I bought a lot of aluminized steel strip and sheet in anticipation of eventually needing to make repairs to Mikuvan.

Making so many different repairs to Vantruck has, in a way, been practicing for that. While I’ve done a lot of mechanical only work to Mikuvan, I’ve not nearly been as comfortable digging deep into it because it’s a much better packaged and integrated experience, not to mention very difficult to find recourse if I mess something up badly due to its rarity in the U.S. market. I’ve already had to source some interior parts from Japan and Taiwan myself because parts are just no longer easily available here – the most recent adventure being securing a set of replacement windshield trim strips because the glass shop could not guarantee being able to get the old pieces off cleanly to replace the windshield. Not to mention, of course, the completely Chinesium cylinder head that’s currently living in it.

Vantruck’s primitiveness at the cusp of the changeover from the “Malaise Era” to the contemporary age of more computerized and polished automobiles, as touched upon in the dénouement of the Regular Car Reviews episode, has made every repair or upfit on it more approachable. I know I can generally transfer the experience if I needed to, even if the methods aren’t 1 to 1. More importantly, its ubiquity even in the modern day means if I completely botch something, it’s a more recoverable error.

In fact, on any day’s regional Craigslist search I can find at least 4 pre-1992 Econoline vans, usually 2 decrepit ones, one “okay” one, and one well-kept one

I’ve actually visited the blue one on the right, and man if I thought I had rust issues….

What I’m saying is, now having witnessed the result of making the sausage, I am not beyond buying an old conversion van and cutting 1/3rd of it off myself. They still sell endcaps for these. In all, these vantrucks are about the weirdest vehicles you can buy which still uses the most common ingredients – Ford truck parts – in their construction.

Enough of the van philosophy! Onto sheet metal repairs.

The plan was to use the area by the van seam as a test weld. If this went of well, the rest will go very quickly. If not, I can still Bondo Castle the whole thing!

I started the patch piece at a distance where it abuts the van seam trim strip, and the difference underneath will be made up by sealant (for someone else 25 year down the line to deal with, I suppose!)

Four little spot welds to hold it down, and I think I generally get the idea.

The mass deletion of a strip above the drip rail and the remains of the body side panel below it then commences. Remember where I said I still had a fire extinguisher and a water sprayer on standby? If there was one part I needed them, it was right here. I basically filled the interior up with sparks. What wasn’t being caught by the tangles of fiberglass insulation was, as I witnessed, shooting straight into the carpet, beyond the areas I pre-emptively wet down near the roof! Oh well.

For the upper slit line, I dug straight down with the cutoff wheel. To separate the gap, I actually approached from the bottom at a very shallow angle. The result was a strip of rusty steel, seen here.

This repair is extremely simple to execute because everything is straight. All I had to do was line up the welding magnets and blast away.

I used the “randomized point welds” approach where you never weld twice in adjacent places or make a single long bead, to minimize heat deformation of the sheet metal. So I’d anchor the strip by opposite corners, then basically switch corners every 3 or 4 trigger pulls.


And after another strip plus a finishing chunk, I’m done here. There’s already like 4x the original spot welds holding the roof on here. Notice the still-present drip rail over the door? That’s staying. I’m not going to shave the whole thing.

All that will happen now is I’ll grind these welds relatively flush and then apply a big Adaptive Fillet of body sealant down the length.

I test drove the process once again by where the van seam is. This was very quick and easy with an already broken-in flap disc which has a bit of an edge radius worn into it. I made sure not to grind enough that I started erasing the root of the weld blob.

Moving down the line. Basically, the area between the patch strip and where the body panel jogs inwards will be entirely filled with sealant. Same goes for the top half. I’m just going to use a popsicle stick as a squeegee / trowel to lay that bead down.

With this process having taken much less time than I figured, I decided to transition to some lookahead work. A lot of other exterior fittings had to come off anyway if I wanted to repaint it, so I was going to just piecemeal address every rust issue as they come up.  First up is the big “I am a classic van” visor. I know it’s hiding something underneath, but have never wanted to check. What I do know is that it some times rains from the upper left corner of the windshield if it either 1. rains too hard or 2. I try to wash it.



It’s held on by a total of 10 screws, two on each side, three in the middle, and three on a little support bracket underneath the …. front awning bit. Luckily, all the screws came out relatively easily despite being somewhat rusty.

Have I mentioned that the hardest part of doing CAR (especially truck-shaped things) is just fighting out what dumb names are given to certain things? And how many of those parts are just named after the guy who invented it?

Anyways, after all the screws are out, you just lift the thing up and……



Yep, this project is getting out of scope fast.

Well that’s no good. A cursory inspection shows that this hole ran deep into the windshield frame, and had a through component on the interior sheet which led directly to an area over the sunvisors. Well that’s why it rains on the inside!

I decided to return to menially applying petrochemical compounds while I thought about what to do here.

Here’s the sealant compound in the “Deposit large blobs and pave over” stage. There’s a matching fillet gfor the bottom edge that didn’t exist yet in this photo. The plan was to let it all cure overnight, and then I just scrape the cured excess sealant off, leaving only the fillets I desire.

While the sealant lines were drying, I decided to  just take care of the rust patch over the driver’s door. There was enough steel left over here that I decided to just Hairy Bondo over the whole affair after cleaning the area up. This is just regular Bondo with short fiberglass strands already pre-baked into it, so it forms a stronger composite not unlike a crappy chopped strand mat.

It doesn’t sand easily due to the fiberglass content, so you use a thing that looks more like a file to get the major cutting done, and then fill in the low spots with regular pink mystery butter.

The final stage is what I call the “cancerous death” looking part, which is after sculpting and sanding down of the regular material. This is called glazing compound or “spot putty” and is intended to fill in very tiny pinholes that might exist because of trapped air from mixing the batch of shame you blobbed on. The juxtaposition of dark red and pink is just kind of gross to look at. This stuff sands very fast, so at this stage I’m using at most 220 grit or so sandpaper.

By the end of this exercise, I had formulated an attack plan for the windshield hole.

Observe, daylight! This is where water was getting in and causing the interior to rain. I was going to equally exploit it to close the hole up. This hole, and actually the empty space above it, meant I could reach tools around from the back.

I don’t have a good closeup photo of the trimming I did to the windshield hole,  so here’s a wide shot that sort of shows what is going on. (Nor it turns out did I take photos of the removal of the chrome windshield trim, which was “Many little broken plastic clips” which fortunately are still made because Ford Trucks Never Change)

I carved away with a Dremel until the metal was solid again, both interior and exterior layers. The black staining is from the same rust conversion treatment which I just sort of do as a matter of course now since I wasn’t going to, say, cut the A-pillar and the front of the roof off to excise it.

So what’s my grand master plan?

Bondo Castle.

Sorry, world. I formed a dam which was roughly the right shape of the windshield frame curvature from a piece of soda can (luckily, enough of it remained to use as a guide).

Then, I ‘primed’ the interior area with brushed on fiberglass resin (a component of Bondo filler) so it would ideally wet out better for more adhesion. Then, I added a Blob of Shame to the hole. However, since I can reach it reasonably with a small popsicle stick from the inside, I was able to create a dome which reached beyond the edges of the steel, again to try and gain area for adhesion.

If I couldn’t reach it from the inside, then this would be one of those Bondo Rocks of shoddy restoration legend, since it would have to be solid and “built up” from the deepest point.

The initial dome was reinforced on both sides with more Fiber-Filled Regret as it cured, gradually reaching the surface enough to level out. I then pulled the soda can barrier off and Dremeled/filed the curvature to shape.


Nobody will know.

Only I will carry this curse.

Okay, that wasn’t nearly as bad as I made it out to be. I think it will be fine, maybe except for getting beaned directly in this repair zone by a flying dumpster. And if that does happen, it will be on dashcam and it will be awesome.


With the entire left side more or less settled, I moved onto the right side. The destruction here luckily was far less extensive, and this was the only trouble spot. It was shallow enough that I just ground it smooth and wire brushed the area and could seal it directly. The sealant on the entire length forward from here was deteriorated, though, so I tore it all out (it wasn’t difficult, since after all it had failed to seal and was just nursing rust underneath) and wire wheeled the gutter. All that will happen to it is application of new sealant.

I decided to keep going and just replace all of the sealant on this side, so I ran all the way down the passenger side A-pillar with the wire wheel.

Technically, at this point, the drip rail operation was all done. But the fun really had just begun! Memorial Day weekend is over with now, and I would take the next few evenings to jump on the roof itself and start dismantling all of the lights and the dysfunctional airhorn, while patching up and priming troublesome areas.  All while plotting the interior rehabilitation and the Next Generation Sex Lights.