New Project - 2012 F150 XTR Rebuild - Page 5 - DodgeIntrepid.Net Forums - Dodge Intrepid, Concorde, 300m and Eagle Vision chat
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post #61 of 89 (permalink) Old 10-07-2016, 11:31 PM Thread Starter
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Things are progressing well. The replacement fender showed up on Tuesday along with my fender flares. The flares look pretty good, better than I expected actually. I wish I would have been able to take a few more pictures but I was pressed for time and had to quickly drop them off at the body shop.



I was at the body shop again yesterday and got to check out the truck. They've got the frame all welded into place. The apron tubes are in place, they just need a few more spot welds. The drivers door was all prepped for paint and they were in the middle of prepping the passenger door. The body shop manager said if everything goes well they're going to have it done by the end of next week.



This week I put out the carpet to dry out a bit since the weather was nice for a few days. It came out pretty good, all it needs is a quick vacuum.









Now I just need to find some time to get the grill surround, the door handles, the mirror caps and the headlight bezels I want painted body colour ready for paint. Monday is a holiday here so I'm hoping that I can do that then. Also, I've decided to replace and repair (with new o-rings) the coolant hoses in order to avoid future leaks like these trucks are prone too.

2011 BMW 335xi (e92) - Black Sapphire Metalic w/ Coral Red Interior
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post #62 of 89 (permalink) Old 10-13-2016, 10:41 PM Thread Starter
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Things are progressing good at the body shop. I stopped by yesterday and all the collision repair is complete. They were getting ready to send it into the paint booth so the truck might just be ready to come back home by tomorrow evening. I wasn't able to get any pictures though, I was in a rush once again.

Last weekend I disassembled the outside handles and the mirror caps in order to start prepping them for paint. I sanded the pieces down with a random orbit sander and 220 grit. That went pretty well, I just need to do the door handle pockets with the 220 by hand and then finish the rest of the parts with 400.



I also got a chance to wash some interior pieces including the dash which was filthy.



WeatherTech mats are all cleaned up too.



Tonight I finished stripping the covers off the front seats and head rest. I did this for two reasons. First off, the seats were filthy just like the rest of the interior. Using a fabric cleaning machine was an option but this way I'm able to put the covers directly in the washing machine. Secondly, I miss the heated seats from the car while driving the truck. With the seat covers off, it'll make installing the heating pads a no-brainer.





The covers prior to a round in the washing machine.



Here's a link to the heaters that I bought, hopefully they work well!

12V Car Seat Carbon Fiber Heated Seat Heater Pad H L Round Switch Kit | eBay

2011 BMW 335xi (e92) - Black Sapphire Metalic w/ Coral Red Interior
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post #63 of 89 (permalink) Old 10-15-2016, 01:44 AM
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Awesome project, love seeing things get rebuilt.
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post #64 of 89 (permalink) Old 10-19-2016, 05:19 PM Thread Starter
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Here's a "teaser" of sorts. I'll write up a longer post with more pictures once she's home!

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post #65 of 89 (permalink) Old 10-19-2016, 08:50 PM
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Can't wait to see the latest update post after that Teaser!
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post #66 of 89 (permalink) Old 10-19-2016, 09:18 PM
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Looks good Steph!!!
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post #67 of 89 (permalink) Old 10-20-2016, 09:52 PM Thread Starter
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Thanks guys!
Alright as promised, here are some pictures of the truck!













I also got the rear bumper end pieces and the fender flares back.





The front bumpers are painted and ready, I just need to make my way to the body shop to pick them up

I ordered up Ford factory remote start kit for the truck which has two new keys (I only got one with the truck). I also ordered what I hope was the rest of the mechanical/maintenance parts required to get the truck up and going. Saturday I'm hoping to swap out some control arms and struts. I got a set of control arms for the drivers side that have less than 1k mile on them. The truck was hit in the rear and totaled out. Usually I'm not a fan of using used suspension components but these are near new with very low miles and well the price was right.



Last weekend I took apart the rear seats and gave them the same deep cleaning as the front set. The seat covers came out looking great so I'm glad I did it. I'm still waiting on my seat heaters to come in for the front too so I won't be putting those together for a while.



Hopefully this weekend I can make some good progress on the truck. It would be nice to get the front suspension done and get the dash in at least.

2011 BMW 335xi (e92) - Black Sapphire Metalic w/ Coral Red Interior
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post #68 of 89 (permalink) Old 10-20-2016, 10:07 PM
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Wow - that paint looks good. Nice job! Seems your project is moving quickly and done right. You'll enjoy that truck once it is done.

Thanks for sharing the rock solid build with us -

Late!
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post #69 of 89 (permalink) Old 12-03-2016, 01:19 PM Thread Starter
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I have been incredibly busy at work as well as around the house but the tuck is progressing slowly. With winter starting I've tried to get the exterior all together so I don't have to work in snow. Anyway's here's a bit of a step by step.

I picked up the front bumper and upper valance cover from the paint shop, I don't think I've posted a picture of them before.



New/ used Bilstein 5100 assemblies that I got from the local parts guy. While I was at it I replaced the drivers side upper and lower control arms.





A few more repair parts as well as the remote start kit.







From there I started putting the rest of the front end back together. I flushed the cooling system with distilled water a few times then replaced the coolant adapter y piece that goes on the block as well as the lower rad hose. I replaced the o-rings in the upper rad hose as well as the coolant overflow bottle hose. The radiator then went back in along with the air box/ coolant bottle and battery and battery box. The AC condenser was put back in and the system got a vacuum to test for leaks too. This was all followed by the headlights and bumper pieces for the following end result.













I ended up having to put new pads on all four corners, they were near the wear limit so I didn't want to risk having them fail the upcoming safety inspection. While I was at it I cleaned up the rotors a bit to remove some rust as well as adjusted the the parking brake. In doing so I've concluded that I need a new drivers side rear parking brake cable but it should be okay for a bit.



I also mocked up one of the new fender flares just to get an idea of what they would look like. Maybe it's the wheels that are on the truck, but I'm not exactly sold on them just yet. I think I need a bit more offset in my wheels but I want to stick with factory wheels. At this point I really wish I would have jumped on that set of wheel spacers that I was offered for $60 a year back. For now I'm not installing the flares until next spring when I have the time to do it right.



With the brakes all done I was able get the wheels put on the truck and move it around the yard. As you'll notice I'm working in the snow again which is ironic. I started the project with snow on the ground and I'll be finishing it with some too!





Now for the interior, I got the dash installed less than a week after the truck was back from the body shop. I had planned to install sound deadning material throughout the truck but I was running out of time. I used the material I had on hand and got the back of the cab done. While I was at it I also built some "filters" our of some foam in hopes of keeping dust out of the cab from the cabin vents. The cab was cleaned up and I installed the minty fresh carpet, seat belts and the majority of the remaining interior trim.









I was on the hunt for a center console to replace the filthy jump seat that came in the truck. I quickly found out that everybody else was also looking for the same thing and I wasn't going to find one without paying dearly for it. So for now I have decided to clean up my original jump seat and just suffer through having that for now. It turned out much better than I thought it would thanks to some pretty strong cleaners.



My seat heater kits came in finally to so the wiring is pretty much all installed. I ruined one of the switches during the install process so I had to order a new one. It was hard to find a spot to put them that made sense and had enough space behind it for the wiring.



Now at this point the critical path item to getting the truck finished is getting the door handles sanded down and painted. This will allow me to get the door panels installed and the exterior sealed for winter winter. I also need to get all the seats back together which means reinstalling the seat covers. The rear bumper still needs to be installed but I'm hoping to get some paint protection film applied prior to that. Speaking of PPF, I also want to get some installed on the front of the truck in order to protect it from paint chips.

Anyways stay tuned for more updates even though they might be slow!

2011 BMW 335xi (e92) - Black Sapphire Metalic w/ Coral Red Interior
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post #70 of 89 (permalink) Old 12-03-2016, 04:42 PM
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Looks great Steph! Nice work, you're going to have a nice pickup to drive very soon!
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post #71 of 89 (permalink) Old 12-21-2016, 06:41 AM
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Great progress Steph still anticipating!
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post #72 of 89 (permalink) Old 12-21-2016, 11:19 AM Thread Starter
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I've been spending most of my free time on house reno's, but I plan on putting some more effort into the truck in the upcoming weeks. I really want to get my door handle cups sanded down so that they can go out for paint finally. That will get me everything I need in order to button up the truck's exterior. Stay tuned for some updates in the new year!
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post #73 of 89 (permalink) Old 12-29-2016, 01:53 PM Thread Starter
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I got some time to work on the truck over the weekend. I got the new/used Ford molded mudflaps installed on the truck. I'm not too keen on the look but at least they're going to offer better protection against stone chips. I also got the seat heaters installed in the front seats along with the cleaned factory cloth covers. I really wish I had the budget to get leather covers but it just wasn't in the cards. I'm hoping to get the rear seats recovered and installed this weekend as well as finish wiring in the seat heaters if my replacement rocker switch comes in. I've got a to-do list made up to get the truck finished so I've got something to work towards now!


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post #74 of 89 (permalink) Old 01-06-2017, 12:43 PM Thread Starter
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Last weekend I got all the seats back together and installed them in the truck. Once I got everything back in I confirmed that the passenger seat heater worked. It gets nice and hot, just the same if not better than an OEM system! I'm still waiting on the drivers side replacement heated switch, hopefully it shows up soon enough. I also cleared all my codes related to restraint system, with the seats missing the system was going crazy. Everything cleared just fine without any lingering issues.





I also got a chance to finish up sanding down the textured finish on the exterior handles and the mirror caps. They're now ready for paint, I'll be dropping them off at the body shop next week!


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post #75 of 89 (permalink) Old 02-24-2017, 04:21 PM Thread Starter
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Slow progress, but the end is in sight. I finally got all the door handles, the cups, and the mirror caps over to the painter. I'm planning to keep the chrome door handles and get the cups PTM. I was ready to have things painted some time ago but then though of having the handles painted too in case I want to get rid of the chrome later. I had already paid to have them done as part of the bill for previous repairs, so it wouldn't cost anything extra. With that in mind I bought a complete other set of textured/chrome door handle assemblies and started to strip the chrome off of my existing handles.





From my experience trying to strip a chrome grill surround last year, I knew the plating on these parts is pretty sturdy. However, after a week all the handles were down to the bare plastic and ready for paint. This time around I didn't dilute the acid so it really sped things up. I still need to get that grille surround painted but I need to strip more chrome off of it first. That will happen later in the spring once I get some nice weather to work outside.

I picked up the painted parts today, I could resist installing the mirror caps! I should have though, since I forgot that I wanted to apply some PPF film first!







Next up is assembling the door handle assemblies with the chrome handle from the new set I bought. PPF film will also be applied to the inside of the cups to keep the nail scratches down. Once that's done I can finally get them installed and get the door panels back on. My replacement heated seat switch came in a week ago so I can finish putting the dash together. I think I'm going to try and shoot for having the truck at the shop for it's alignment and safety inspection by the end of March. That will make it exactly one year from when it showed up at my place!

2011 BMW 335xi (e92) - Black Sapphire Metalic w/ Coral Red Interior
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