1969 Ford F100 / 2002 Ford Lightning "Thunder's Truck"
 

When a customer called our shop suggesting his idea of mating a 1969 F100 Ranger with a 2002 Ford Lightning, we thought it was a cool idea but thought we would be taking the engine and transmission from the Lightning and putting them in the '69 truck. After doing much evaluation of the amount of time and parts it would take to make a '69 F100 not only have the power of the Lightning, but also the cornering ability, comfortable ride, braking, and reliability, he proposed we do a complete body swap on to the Lightning frame.

http://v8tvshow.com/1969_Ford_Lightn....12.14_002.JPG

He's owned the 1969 F100 Ranger for many years, and this example is a very clean truck with 54,000 miles. It has a 390 V8, and a three speed manual on the column. While attending an auto auction, he came across a 2002 Ford Lightning that had been totaled by an insurance company, but had only received minor damage from a low-speed front end impact.

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http://v8tvshow.com/1969_Ford_Lightn....13.14_006.JPG

We suspect the reason for the total was that the radiator, air-conditioning coil, transmission cooler, and other core support mounted items had been damaged, and they were expensive to replace.

He bought the truck, and even with the damaged components, it still ran and drove. It was then measured to make sure the wheelbase was square, removing any suspicion of frame damage and it was decided that this would be a great candidate for the body swap.

http://v8tvshow.com/1969_Ford_Lightn....13.14_001.JPG

The build plan also included a few upgrades to the 1969 truck body, including a Vintage Air system, an idiot tilt steering column, upgraded audio, Dakota Digital VHX gauges, and a few other creature comforts.

When both trucks arrived in the V8 Speed & Resto shop, we were very impressed with the quality of the '69. It has been repainted and some of the trim is a little faded, but overall it is a very nice truck. The plan is to leave the exterior as it is.

http://v8tvshow.com/1969_Ford_Lightn....12.14_009.JPG

Measurements were taken to compare the wheelbase, track with, and other crucial dimensions to see if the swap would be feasible.

http://v8tvshow.com/1969_Ford_Lightn....13.14_015.JPG

We concluded that this could work, so disassembly of the Lightning began.

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The electrical system was disconnected, as were the brake lines, steering linkage, engine harness, fuel lines, emergency brake cables, and anything else tying the body to the chassis.


http://v8tvshow.com/1969_Ford_Lightn....14.14_016.JPG

Soon, the crew had the Lightning cab and bed off the frame.

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Next, they brought in the '69 F100 to do the same trick of removing the cab and bed.

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The Lightning chassis was slid under the '69 Cab and the test fitting began.

http://v8tvshow.com/1969_Ford_Lightn....14.14_033.JPG

http://v8tvshow.com/1969_Ford_Lightn....14.14_034.JPG

Now thats kick ass!

Thanks, it's going to be a sleeper for sure!

Cool project Kevin!! This will take a few people by surprise for sure!

This should be a fun build to watch. I have a 70 F100, and while a cool truck, the suspension etc is really lacking. I will be following closely.

Glenn

Nice project. It should be quite the ride when your done.

subscribed!!! looking forward to this!

Thanks for the interest, guys! We were a little aprehensive about this one at first... or should I say "I" was aprehensive. The customer was convinced it would be an easy project, but we all know nothing is easy. Good thing we have a crew that is capable and super enthusiastic!

As we lowered the 1969 cab down onto the 2002 Lightning chassis, it looked like the track width on the Lightning was going to be pretty close to the outer fender edges on the 1969.

http://v8tvshow.com/1969_Ford_Lightn....14.14_038.JPG

Our first interference was the shape of the back of the '69 cab that allows the cab corners to hang down around the frame. The Lightning frame is wider than the '69 in this area, so the first cut on the '69 cab was to open up these corners.

http://v8tvshow.com/1969_Ford_Lightn....14.14_042.JPG

http://v8tvshow.com/1969_Ford_Lightn....14.14_046.JPG

[img]http://v8tvshow.com/1969_Ford_Lightning/slides/1969_F100_MP_10.14.14_049.html

Once we modified the back of the cab, we were able to lower it further down onto the lighting chassis.

http://v8tvshow.com/1969_Ford_Lightn....14.14_057.JPG

http://v8tvshow.com/1969_Ford_Lightn....14.14_058.JPG


Our next point of interference came in the front, where the 1969 inner fender wells seemed to interfere with the upper control arm mounts on the Lightning. We cut some simple notches in the inner fenders, and the cab and landed on the '02 chassis. The cab mounts are not in the exact same position, but they were close! We cut the front core supports off the Lightning frame, with anticipation of making our own core support and bumper mounts later.

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http://v8tvshow.com/1969_Ford_Lightn....14.14_081.JPG

Awesome.
Sleeper truck!

Very cool


Marty-mj
www.garagescene.net www.syborgtwinturbo.com www.2ndcamaro.com

The crew was pretty impressed how the wheel fit in the front wheel well, and it didn't look like very much fore-aft adjustment would be needed.

The cab is still not all the way down on the frame in this picture, so this is not ride height.

http://v8tvshow.com/1969_Ford_Lightn....14.14_064.JPG

Bringing down the cab left this fitment:

http://v8tvshow.com/1969_Ford_Lightn....14.14_070.JPG

With the cab "in the ballpark", the crew was eager to test fit the '69 bed on the Lightning chassis. We knew the wheelbase of the Lightning was approximately 5 inches longer than the 1969 truck, so we anticipated a fitment issue there. The crew unbolted the '69 bed and carried it into the Lightning chassis.

http://v8tvshow.com/1969_Ford_Lightn....14.14_078.JPG

http://v8tvshow.com/1969_Ford_Lightn....14.14_086.JPG


Once they set the '69 bed on the Lightning chassis, it became obvious that some modifications would be needed to have it fitted properly. The Lightning frame kicks up approximately 3 to 4 inches, raising the bed far above its original orientation to the cab.

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We also noted that this the gap between the cab and the bed was approximately 5 inches, so the crew began to strategize on how to make this fit.

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http://v8tvshow.com/1969_Ford_Lightn....14.14_084.JPG


At this point, it was determined that perhaps the cab should be "locked down" into its final position before the crew made any changes to the frame to fit the bed. Little spacers were made to simulate cab mounts to pick up the backside of the cab, and the cab was located longitudinally on the Lightning frame.

http://v8tvshow.com/1969_Ford_Lightn....15.14_019.JPG

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This truck will not be using the Lightning wheels when completed, but it will use wheels of the same size to utilize the stock Lightning tire dimensions. This way, we will be sure that the gear ratio will match that is designed for the lighting.

http://v8tvshow.com/1969_Ford_Lightn....15.14_021.JPG

It turns out that the front cab amounts will be usable on the Lightning chassis, and the crew position and '69 cab over these. Holes will have to be drilled for the mounts, but if it should work.

http://v8tvshow.com/1969_Ford_Lightn....15.14_008.JPG

The crew rolled the chassis truck outside to be able to step away and look at it.

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It looks good Kevin. Will you shorten the frame where it levels out under the bed after that rise behind the cab?

We'll show you what the crew came up with to make the bed fit and align with the cab. We ended up moving the wheelbase and shortening the frame.

With the cab bolted in place at the front cab mounts, the crew felt it was safe to begin addressing the wheelbase situation. They drilled out and ground off the rivets holding the stock leaf spring mounts to the chassis, and measured the frame to see if the rear suspension could be moved forward to shorten the wheelbase. When the wheelbase seemed to be in the right place, they tack welded the brackets back on the frame to evaluate.


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Next, the crew needed to address the bed height situation. This was done by grinding notches in the transverse supports below the bed.

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http://v8tvshow.com/1969_Ford_Lightn....21.14_006.JPG

Cutting the notches allowed the bed to come down approximately 2 inches, which helped, but was not quite enough. Next, the crew shim the back of the cab upwards to make up the difference in height. At this point, the wheelbase is nearly correct, the cab in bed are in alignment, and the truck has a slight rake which is exactly what the customer wanted.

http://v8tvshow.com/1969_Ford_Lightn....21.14_008.JPG

http://v8tvshow.com/1969_Ford_Lightn....24.14_004.JPG

We were all pleased at how quickly the major pieces came together on this project. It is far from finished or driving, but it is really coming together nicely. The rear track which fits under the bed, the front wheels fit comfortably in the front fender wells, in the truck looks natural. At this point, it looks like a '69 truck with Lightning wheels! This one is going to surprise more than a few people!

http://v8tvshow.com/1969_Ford_Lightn....24.14_005.JPG

http://v8tvshow.com/1969_Ford_Lightn....24.14_007.JPG

Looks great!

It looks perfect, but its what we've come to expect. You guy's do great work. No one will be the wiser.

Incredible! You guys are making it look easy.

Thanks guys, we have a talented crew that does make it look easy. We caught a few brakes on this one also... we were expecting to have to narrow the track width, but got lucky!

Next it was time to solidify the chassis. The crew removed the X shaped crossmember and repositioned it to work with the shortened frame.

http://www.v8tvshow.com/1969_Ford_Li....05.14_003.JPG

Originally, the leaf springs were riveted to the frame, but we decided to weld everything solid. Adam made some closeout panels to box up the rails to prevent the leaf spring perches from twisting the frame rails.

http://www.v8tvshow.com/1969_Ford_Li....05.14_002.JPG

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Kevin
Great build! Paint the rims black and it"s time to sneak up on an unknowing Camaro owner at a stop light.

Mike

Ha! The owner wants a vintage looking wheel, but it's hard to find in the 5 x 135mm pattern. Thanks for the kind words.

Next, he fabricated a new upper shock mount, as the position of the mount had changed slightly, and the two shocks were not in the exact same position. The drivers Side upper shock mount was recessed into the crossmember to ensure that it would have the same travel as the shock on the passenger side.

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http://www.v.JPG[img]8tvshow.com/196....08.14_019.JPG

Next, a tubular rear cab mount/crossmember was fabricated to support the rear part of the cab.

http://www.v8tvshow.com/1969_Ford_Li....09.14_002.JPG

Awesome truck

Looking Good.

This is a great build and your crew made it look so straightforward and easy. I kind of like the stock Lightning rims on the truck.

Very cool, great work. Hope we get to see the fully finished product.

Great work as usual!

Thanks guys!

Pretty cool build!!!!

A few more shots of the new rear cab support.

http://v8tvshow.com/1969_Ford_Lightn....09.14_005.JPG

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