66 Double Cab Restoration

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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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66 Double Cab Restoration

Post by heli-easy » Mon Feb 17, 2014 11:15 pm

I bought this Double Cab up in Tacoma Washington. It was in really bad condition. I don't have tons of money but really wanted a DCab so this was the best I could find for the amount I have. I figured it would be a learning experience at least. I have no professional experience with this stuff, this is the project I'll be learning on so forgive me if my work isn't perfect. This being said though I have restored a few bugs, but nothing this extensively damaged.

This project took about a year and a half to complete. I took a lot of pics but never posted them till now. Hope this give someone else some encouragement on their own project. I did all of this in my garage.

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After stripping a lot of the old paint and bondo, it was time to push into the garage. This is going to take some power tools.
Last edited by heli-easy on Fri Feb 28, 2014 11:51 am, edited 2 times in total.

heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Mon Feb 17, 2014 11:36 pm

Pulled engine

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and tranny

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built a rotisserie

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removing the beam to attach the rotisserie and to rebuild it.
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Rotisserie attached and ready to go

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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Mon Feb 17, 2014 11:38 pm

removing rusty bed panels

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drilled tons of spot welds.
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special tool to split the welds
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All the bed panels removed
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A view of the floor below,
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Measured the bed supports before removing them
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The rotisserie has a gearbox that holds it at whatever angle its set at
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Engine on the stand to begin stripping it
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Mon Feb 17, 2014 11:52 pm

Started work on the drop gates. Good on the outside. Inside, not so good.

The gates are just about scrap. That's why I started on these. Figured I couldn't mess up any worse. Plus if I can do these the rest should be possible.
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Last edited by heli-easy on Mon Feb 17, 2014 11:59 pm, edited 1 time in total.

heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
Contact:

Re: 66 Double Cab Restoration

Post by heli-easy » Mon Feb 17, 2014 11:55 pm

The edge was a pain, had to rebuild it.
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 12:05 am

After all the work on the gates I decided to work on something a little easier. This is the inside panel of the rear valence. It was worn through where the exhaust must have been rubbing on it.
Cut out the damaged spot.
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Trying this punch/ seaming tool from Harbor Freights
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 12:13 am

Had a cut out from a previous owner putting a big after market stereo in the dash.
Another small project that I can finish easily. Tired of finding rust on the car.

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Used this bar to bend my repair in a large radius.
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 12:19 am

More rust removal.
Bed supports and cargo floor.
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Bed support with the gas tank separation panel frame.
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mountainkowboy
Posts: 341
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Location: Socal

Re: 66 Double Cab Restoration

Post by mountainkowboy » Tue Feb 18, 2014 12:30 am

I WANT ONE! :)
71 Ghia Coupe........For Sale
71 Super-Beetle Convertible.....returning to DD status
63 IH Scout 80 (beater)
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heli-easy
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 12:32 am

This rocker is a common rust area. Mine was not even usable.
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This bed support was rusted bad on the inside.
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Cut it open and sand blasted it.
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Cut spare tire area. Rust as heck
Blasted the floor members and primed.
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More rust inside the C pillar
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Started installing the inner rocker support.
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Sand Blasting the underside of everything
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 12:42 am

Fabricating the hat sections for bed supports and the floor supports.
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Replaced the forward bulkhead and hat suport.
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Replacing the rocker and door frame.
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Replaced the back floor bulkheads
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 12:56 am

Made a repair for the bottom of the inner back door sill.
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heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 1:04 am

Fabbed a new bed cross support. Looked like is made to take a lot of weight so made it out of .090 steel.
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Fixing the lengthwise bed supports that I cut out earlier. They were rusted through on the bottom and top. They are a boxed channel.
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Installed them

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stealth67vw
Posts: 529
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Re: 66 Double Cab Restoration

Post by stealth67vw » Tue Feb 18, 2014 1:40 am

Damn Rob, I had no idea you had that much work into your double cab. I thought you just replaced the floors and rockers. I've cut up better buses LOL. I applaud your effort, you gots mad skills for sure. I remember you bringing a section of your fabbed section of bed ribs over when you bought the trans from my bug when you started this project. I can't imagine how much you've spent of cut off wheels, grinding discs, mig wire and gas. Good job man.

heli-easy
Posts: 87
Joined: Mon Nov 15, 2010 8:29 pm
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Re: 66 Double Cab Restoration

Post by heli-easy » Tue Feb 18, 2014 2:16 am

Thanks,
ya I used a lot of supplies!
I had all this on my own website but apple discontinued their web app, so I lost my website.
I recently organized all my photos. So figured I'd share it all. Its a lot to go through tho.

:)

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