Milling over the idea one day, Editor Fortier suggested using caged nuts for some of those hard to reach fasteners. Naturally, he suggested this AFTER I had all the front sheetmetal assembled. Not one to shoot down a good idea, though, I decided that it would behoove me to disassemble the fenders and front end pieces and install a few caged nuts I picked up at the local hardware store. This solved three problems. One, the original fender-to-inner-fender hardware consisted of a series of carriage bolts held in place by square holes broached in the inner fenders. Most of the holes were acceptable, but there were a few that were very close to becoming rounded and thus unable to hold the carriage bolt in place. This would make bolting up the front fenders properly impossible using the stock carriage bolts without repairing the holes, and I didn't have a square drill bit, nor have I ever seen one. A repair would mean welding up the holes, drilling them undersize, and broaching the hole with a square file, which sounded like a lot of work. The second solution this presented was my problem of bolting up the fenders single-handedly. Though the carriage bolts did not require a wrench at both ends, it still meant you had to hold the fastener in place while holding up the fender and starting a nut on the inside of the fender, a daunting task, to say the least. The third solution was that the original carriage bolts did not allow much movement when it came time to line up the fenders with the cab, valence, and upper grille panel. The caged bolts had a quarter-inch or so of movement that allowed the fenders to slide back and forth if need be, which turned out to be very helpful when it came time to line everything up.
Aside from the installation of a handful of caged nuts to ease installing the fenders, the rest of the sheetmetal was assembled just as Henry's boys originally intended ... this time, though, with stainless fasteners. One quick note about stainless fasteners before we continue, however, is the fact that it is absolutely essential to use an antiseize lubricant on all fasteners, regardless of the load rating. This is necessary because stainless steel has a tendency to gall due to the fact that it's softer than medium carbon steel. While it may seem harder, this is only because it work-hardens, so use antiseize lubricant liberally. That said, let's get that front end bolted up so this thing looks more like a truck and less like a bare cab sitting on the chassis.