So about a month ago, I pulled the trigger on a nice looking '96 Ford F-150 4x4. Had a friend check it out and he gave it a somewhat clean bill of health. Got a ride to Harrisburg, PA, picked up the truck, and drove back to Ann Arbor the same day. Then I started learning its quirks.
It had a few things I didn't expect, but for the most part, I was pleased.
I installed new steering linkages, tie rods, and ball joints.
That was when I found out the front u-joints were shot. And then I cracked the axle yoke while trying to get them out. Found another set locally though and was able to get back on track. While doing that, found that the front shaft u-joints were also shot.
I also had to replace the front fuel tank (no pictures of that). Getting the fuel lines off (after finding the proper tool, which was a challenge in intself) was a PITA. Rear tank seems OK for now.
I rebuilt the 4x4 shift lever. It was frozen and wouldn't compress to get into 4-low. The rubber boots were torn causing grit and water to get in. I fashioned some new boots out of a bicycle innertube - GRM style (pics later hopefully). I also changed the transmission and transfer case fluid and resealed the diffs.
The truck had very little rust, which is the main reason I bought it. I knew once the deferred maintenance was done, I would have a nice, reliable truck.
This weekend's task was to get rid of the rust and prevent future rust.
Passenger side rear fender:
Driver's side rear fender:
(not final bondo - it was much smoother)
I cut both the inner and outer fender rust out. I only patched the outer fender. I figured I will leave the inner fender open so I an hose it out occasionally to prevent future rust. Only issue I had with the welding was I used the wrong gauge, it was too thin. I also learned I need a lot more practice with sheet metal. However, not too much bondo was needed.
After the fenders were all patched, I masked and painted with bedliner paint. I went with Herculiner after reading the reviews here and others online.
First was masking.
Driver's side:
Once I got the arc looking nice, I made a template for the passenger side.
I did the same for the rear.
I painted the door jambs and lower inside of the door as well.
And this is where I left it this weekend.
I also put in new headlights to replace the old dull and faded ones. Removed the roof visor (I used stainless steel sheet metal bolts and clear silicone for the time being to plug the holes).
The only thing keeping it from the road now is waiting for the paint to dry so I can close the doors and an aligning the front end! Then I have a bunch of little projects that aren't as time consuming (like new speakers, rewire the stereo, find a small rain leak, etc.). But the big stuff is finally done! Not sure if I'm going to put the brush guard back on or not. It's fairly rusty and would need paint.
All major work completed. Now its onto small stuff, but nothing keeping it from DD service for now. I'm going to drive it this week to find any more bugs then go back to the RX-8 until weather starts to turn bad. 
