JMcFly’s XLT Simple Restoration and Mods

[JMcFly]

I just picked up this 2002 XLT 4 cylinder with 5 speed. She has 217k miles and is pretty straight. Not showroom clean but for 24 years old it’s not bad, needs a good interior detailing.

I bought it knowing it needs the clutch done since the slave failed and it’s sat for several months by the last owner.

I moved it to my house, a block over from my friend I got it from, and started tearing into it. Pulled the battery since it’s flat and 5 years old so I’ll get a new one. Cleaned up the battery tray and did a quick paint job. I have a POR15 kit somewhere I’ll use later.

The rear of the cab roof where the trim pieces are needs to be pulled and surface rust treated/painted. There’s some dents on the roof and peeled paint that needs rust cleaned up and painted. Easy work

But I noticed some rust above the doors and peeled the gaskets back to find this

I have a little 120v flux core welder and the rust seems to be above the gasket lip. So I should be able to find donor metal and cut out some replacement sections and tac it all in. I’ve never worked on sheet metal, mostly thicker metal tubing so I’ll have to get extra to test and practice on. Any advice is welcome. I hope this isn’t a death sentence for the truck. Frame and everything else is very very solid

Center console was removed from the truck. Looks like a bolt ripped out from the sheet metal, I’ll have to get pics


My modification plans are easy. Better seats, a 2/3 or 4/5 drop with tasteful wheels. I haven’t browsed enough to see what’s out there but I want to make it into a nice little truck I can still use as a truck.



This will probably cut into my other project which is a full scale bleeping and blooping R2D2 which I’ve 3D printed. I didn’t design it, someone else did. But I build Star Wars props as well. Cars have always been my main hobby

 

[franklin2]

If you find a donor for the roof pieces, I think I would cut the donor roof off whole (make sure it's in good shape of course). Then I would take it home and start debating and studying; Would it be easier and better to just cut the whole roof off your truck and splice the donor roof in place? Some of the interior would have to come out, the windshield would have to come out. I was thinking you could splice it at the A pillars and the B pillars. Unless you came up with a better idea.

The white paint should be easy to redo. You could spray can it and then buff it out.