The joys of rebuilding a 63 year old composite body.

Questions and requests about Technical Repairs of the CCKW
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Bill_Wolf
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The joys of rebuilding a 63 year old composite body.

Post by Bill_Wolf »

What Fun! :roll:

My truck was a Norwegian return. I believe the body is original as it has the large head carriage bolts (most rust beyond saving). The bed was so rotted that if you stepped on it and not on the steel wear rods you would go through to the ground.

Image

Off she came prior to any sand blasting work. It made it much easier to get to the drivetrain and frame parts.

As the truck nears completion I am now on to the bed. It was my original intention to restore this using original components. The $2500+ cost of the raw Oak alone to do the bed was not unexpected but still a shock. I opted for the cheaper way of using readily available 2 by Pressure Treated Lumber. It was 10% of the Oak cost.

For wood that will be trampled on and mostly covered with Cargo, troop seats, and a tarpaulin I could not see spending the extra $2300. Also $2500 is not in the budget at this time. That would have put off doing the cargo body until at least next summer. I want to drive and use this baby...not look at it sitting in the yard! If I don't like the way it wears I can always yank it off and put down the authentic stuff. $200 is not too much of a sacrifice. So I am using PT.

I also found that the rear compartment floor, tongue and groove pine, was rotted out and needed to be replaced. That was done in PT too as viewed below.

Image

The trouble with the composite bed is that there is 7 different widths of the boards in 14 pieces. Also with PT (and green oak) there will always be some shrinkage. So every piece had to be custom measured and cut to a fit to measure width. No mass production here.

It required a custom rip for width and then the use of my router table to cut the "groove" that the steel wear plates would fit into. You can see from the pics that the bolts go to pre-drilled holes in the steel stringers to hold down the steel wear rails . These don't go through the wood. However there are some that just go through the wood only but not on every board.

Image

I used standard carriage bolts bought over the internet in bulk. I know that large head carriage bolts are what was originally on the truck. But the cost difference of 5 times eliminated the large head. Again because in most cases the bed won't be seen. Bolts, nuts, washers in bulk ran $200.

Image

The other issue is that it is difficult, if not impossible, to use rachets on the 3 outside boards on each side because of the clearance on the stringers. I was lucky enough to have a box wrench with rachet built into the box side, a real life saver.

Prior to the wood installation the bottom of the board was hand painted with OD paint.

So that is my plight. Lots of work, easy work, but very time consuming. Total time per board for the 4 boards is about 1 hour each, cutting, routering, and installation.

Just thought you all might like to know.

Bill
1945 GMC DUKW
1942 Chevy 125 Crash Truck from Dow AAFB,
1944 Chevy 325 Fire Truck
1942 WC-54 Ambulance
1944 M29C Weasel (x6)
1945 CCKW 353 A2 Open Cab "Air-portable"
1943 M5 High Speed Tractor
1942 Sperry Searchlight setup with GE Generator
1942 M-1 Fruehauf Searchlight Trailer (G221)
1942 M-17 Fruehauf Quad 50 Trailer (G221)
1942 M-10 Ammo Trailer (x3)
194? Steel Ben Hur (x4) 194? Wood Ben Hur (x2)
1945 Case VAIW-3 Aircraft Tug
1943 Case VAI USAAF with Mower
1944 Clark CA-1 Airborne Dozer
1944 PE-95G, 1944 PE-99B
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Post by dr deuce »

Better you than me.... :D
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1943 CCKW closed cab cargo w/M32 MG mount
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Karoshi
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Post by Karoshi »

The joys of rebuilding a 63 year old composite body.

Hey, our health service did it for me! Plastic this plastic that, hearing aids, pace maker.

I thought it was worth it.
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Post by KEVINABR »

Fantastic work and a great job you have done, using the pt timber would have been my choice too.
please post more pics when she s finished Bill :D
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Post by John V Cliche »

Kinda different doin' wood work HUH :lol:

Looks like your making good progress.

Did Jeff blast and paint the searchlite tailer this summer?


John
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Post by Bill_Wolf »

I can see it starting already...

Just waiting for Doc and Barry to chime in. :lol:

There was too much rain and Jeff was too busy chasing girls.... :roll:

Depending upon the weather next week I may get the searchlight trailer started then.

Bill
1945 GMC DUKW
1942 Chevy 125 Crash Truck from Dow AAFB,
1944 Chevy 325 Fire Truck
1942 WC-54 Ambulance
1944 M29C Weasel (x6)
1945 CCKW 353 A2 Open Cab "Air-portable"
1943 M5 High Speed Tractor
1942 Sperry Searchlight setup with GE Generator
1942 M-1 Fruehauf Searchlight Trailer (G221)
1942 M-17 Fruehauf Quad 50 Trailer (G221)
1942 M-10 Ammo Trailer (x3)
194? Steel Ben Hur (x4) 194? Wood Ben Hur (x2)
1945 Case VAIW-3 Aircraft Tug
1943 Case VAI USAAF with Mower
1944 Clark CA-1 Airborne Dozer
1944 PE-95G, 1944 PE-99B
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Post by John V Cliche »

weasel_nut wrote: Jeff was too busy chasing girls.... :roll:


Bill
Tell Jeff he needs to find a girl that likes to get dirty :shock: :wink:

506 :lol:
42 Chevy G7117
44 Ford M20 armored car
44 CCKW 353 A1 660 gal Tanker
45 CCKW 353 B2 Air-portable
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Post by Barry Churcher »

As much as I live for giving you the raspberries I can't say much other than "Great job Bill." 8) The PT wood does a nice job and when painted who will know? Here in Canada the PT wood looks like crap. All our good stuff goes to the US and we are left with crooked, knotty sh*#. It helps our economy though and we are left with more $$$ to spend on our trucks. :D
Cheers,
Barry
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Bill_Wolf
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Post by Bill_Wolf »

UPDATE:

The floor is nearing completion.

$226 worth of wood.

$87 worth of bolts

1/2 Gallon of paint.

Took about 18 hours to do the boards and rebuild the wood storage box behind the rear door.

Good thing I only have to do this once. :roll:

Image

Image
1945 GMC DUKW
1942 Chevy 125 Crash Truck from Dow AAFB,
1944 Chevy 325 Fire Truck
1942 WC-54 Ambulance
1944 M29C Weasel (x6)
1945 CCKW 353 A2 Open Cab "Air-portable"
1943 M5 High Speed Tractor
1942 Sperry Searchlight setup with GE Generator
1942 M-1 Fruehauf Searchlight Trailer (G221)
1942 M-17 Fruehauf Quad 50 Trailer (G221)
1942 M-10 Ammo Trailer (x3)
194? Steel Ben Hur (x4) 194? Wood Ben Hur (x2)
1945 Case VAIW-3 Aircraft Tug
1943 Case VAI USAAF with Mower
1944 Clark CA-1 Airborne Dozer
1944 PE-95G, 1944 PE-99B
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ohhhh it's too hard..... redoing a 63 year old composate bed

Post by Colin Britton »

Bill,

The only thing I have to say is plated carrage bolts? That will be a pain as with use the paint will be chipped off and bright shiney carrage bolts will be giving off light.... :shock: No natural metal or unplated carrage bolts available?
Other than that I have to say AWESOME JOB!!!!!!! The bed looks great and by the sounds of it you retain all your fingers.... Good job.
Sorry to let you down on not beating you up on the lumber issue/type used in your project. Hope you did'nt have your hopes up..... :D
ATW,
Doc Britton.


1945 353-B2 W/W with 1943 Trackson Co. M-36 Gun Mount
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1943 Steel body Ben Hur trailer
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Post by thierryb »

You did a wonderful job, Bill.
One question : the boards are different in size. I’ve noticed that on other trucks in the past. Is there a reason for some boards being wider than others :?:

Thierry.
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Post by Bill_Wolf »

thierryb wrote:You did a wonderful job, Bill.
One question : the boards are different in size. I’ve noticed that on other trucks in the past. Is there a reason for some boards being wider than others :?:

Thierry.
Thierry,

I measured the rotted boards prior to removal and duplicated the width. I do not know what the intention is for making them different widths. It sure was a pain having 7 different widths to deal with.

I would be interested in the reason too.

Bill
1945 GMC DUKW
1942 Chevy 125 Crash Truck from Dow AAFB,
1944 Chevy 325 Fire Truck
1942 WC-54 Ambulance
1944 M29C Weasel (x6)
1945 CCKW 353 A2 Open Cab "Air-portable"
1943 M5 High Speed Tractor
1942 Sperry Searchlight setup with GE Generator
1942 M-1 Fruehauf Searchlight Trailer (G221)
1942 M-17 Fruehauf Quad 50 Trailer (G221)
1942 M-10 Ammo Trailer (x3)
194? Steel Ben Hur (x4) 194? Wood Ben Hur (x2)
1945 Case VAIW-3 Aircraft Tug
1943 Case VAI USAAF with Mower
1944 Clark CA-1 Airborne Dozer
1944 PE-95G, 1944 PE-99B
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