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1953 Ford F-100 Body Modifications - Behind The Scenes At The Roadster Shop

Mike Crimaldi's '53 F-100 Part 5: Subtle And Smooth Body Mods
1953 Ford F100 Body Modifications Rear Fender
The Roadster Shop decided... 
   
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1953 Ford F100 Body Modifications Rear Fender
The Roadster Shop decided to widen the rear fenders, but not in the way you might think. A straight line marked on the fender's flat "horizontal" plane shows where it's going to split open like a hot dog in a microwave.
1953 Ford F100 Body Modifications Pros Pick Fender
A body saw makes short, steady... 
   
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1953 Ford F100 Body Modifications Pros Pick Fender
A body saw makes short, steady work of almost severing the new Pro's Pick fender in half.
1953 Ford F100 Body Modifications Metal Work
After eyeballin' the situation... 
   
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1953 Ford F100 Body Modifications Metal Work
After eyeballin' the situation long enough, the Roadster Shop determined that opening the very back of the fender 1 inch would accomplish what they were after.
1953 Ford F100 Body Modifications Roadster Shop
With the new gap well clamped... 
   
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1953 Ford F100 Body Modifications Roadster Shop
With the new gap well clamped in place, the Roadster Shop held up a strip of sheetmetal on the back side and traced the gap onto it.
1953 Ford F100 Body Modifications Sheetmetal Shears
Sheetmetal shears quickly... 
   
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1953 Ford F100 Body Modifications Sheetmetal Shears
Sheetmetal shears quickly trimmed the new sliver of steel that will be added to the fender.
1953 Ford F100 Body Modifications Tig Welding Tool
Once all the trimming was... 
   
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1953 Ford F100 Body Modifications Tig Welding Tool
Once all the trimming was done to ensure that the new piece fits perfectly into the gap, it was tacked in place. A job like this is probably better left to a TIG welder rather than a MIG welder's hard bead. Trying to fit a piece this long can be a tricky job, so cutting it into two or three pieces can make it much easier.
1953 Ford F100 Body Modifications Mig Welder
The TIG welder leaves a softer... 
   
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1953 Ford F100 Body Modifications Mig Welder
The TIG welder leaves a softer weld than a MIG welder, it can be worked like the sheet-metal that surrounds it, and it can be hammer-welded with a body hammer and dolly to minimize warpage.

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