Project Basket Case: Custom Cut Glass & Final Assembly

(NARRATOR)>> WHEN YOU CHOP A TOP YOU BETTER BE READY TO CUT GLASS. TODAY OUR EXPERT SHOWS US HOW IT'S DONE ON OUR FORD RESTO MOD. PLUS WE'LL GET HER OUTSIDE TO MEET THE FANS. ( ) THIS IS TRUCK TECH AND I LOVE IT!

(LT)>> WELCOME TO TRUCK TECH. TODAY WE HAVE TWO VERY DIFFERENT MAKES OF TRUCK, CHEVY AND FORD, IN TWO VERY DISTINCTIVE STYLES OF BUILD. AND I CAN SAY IT'S BEEN A BLAST WORKING ON BOTH OF THESE CLASSIC AMERICAN PICK UPS.

(JEREMY)>> I AGREE, AND WITH OUR '71 C-10 WE'LL JUMP BACK ON IT AND WE'LL GET IT READY FOR THE STREET, BUT FOR TODAY WE'RE COMMITTED TO FINISHING OUR '55 F-100, AT LEAST CLOSE TO IT.

(LT)>> WE'LL GET THERE. YOU KNOW I'VE ACTUALLY SEEN GUYS ABANDON PROJECTS WITH CHOPPED ROOFS HALF WAY THROUGH SIMPLY BECAUSE THEY COULDN'T FIND A PIECE OF GLASS TO FIT THE WINDSHIELD OPENING.

(JEREMY)>> WELL THAT'S NO WORRIES FOR US BECAUSE TODAY WE'VE GOT GLASS GUY CHICAGO BRIAN HARDING IN TO CUSTOM CUT A WINDSHIELD FOR US. NOW I KNOW YOU WORKED IN THE GLASS BUSINESS FOR A LITTLE WHILE. HAVE YOU EVER ATTEMPTED TO CUT A CURVED WINDSHIELD?

(LT)>> YOU KNOW I'VE MADE PLENTY OF FLAT LAMINATED WINDSHIELDS FOR YOU KNOW THE '20'S AND '30'S HOT RODS THAT HAVE THE FLAT FRONT, BUT I'VE NEVER TRIED TO CUT DOWN A PIECE OF CURVED LAMINATED GLASS.

(JEREMY)>> IT DOESN'T LOOK EASY.

(LT)>> I WOULD SAY NOT.

(JEREMY)>> BUT BEFORE WE GET TO WORK WE HAD A LITTLE FUN LAST WEEKEND WHEN WE PUT HER IN THE TRAILER. WE TOOK HER DOWN THE STREET TO A LOCAL CAR SHOW JUST TO GET A FEW REACTIONS MID BUILD. THE REAR FENDERS, THEY'RE ORIGINAL, STRETCHED A COUPLE OF INCHES.

(LT)>> WE BRUSHED IT ON AND WIPED IT KIND OF LIKE

YOU WOULD A WOOD STAIN.

(JEREMY)>> YEAH IT'S CHOPPED A LITTLE BIT CAUSE

THESE TRUCKS, THEY'RE WEIRD.

THEY'RE SO TALL RIGHT THERE IN THE CAB, YOU KNOW? AND THEY'RE SHAPED AWKWARD TOO.

(LT)>> WELL IT'S BEEN A LONG JOURNEY TO GET TO THIS POINT AND WE'RE ACTUALLY REALLY EXCITED TO GET THIS THING OUTSIDE. IT'S A LITTLE BIT WET TODAY BUT IT'S JUST KIND OF REWARDING AFTER YOU SPENT ALL THESE HOURS WORKING ON A PROJECT TO SEE IT OUTSIDE, GET PEOPLE'S REACTION, AND STEP AWAY FROM THE SHOP A LITTLE BIT, AND PUT THE TOOLS DOWN AND GET OUTSIDE. ( )>> BEAUTIFUL, ABSOLUTELY STUNNING, STRAIGHT, STANCE RIGHT, I LOVE THE WHEELS. ( )>> DID YOU RECOGNIZE WHAT'S UNDER THE HOOD? ( )>> I DID YEAH, IT'S A LITTLE ECOBOOST TWIN TURBO FORD MOTOR. SO YEAH, THAT DEFINITELY CAUGHT MY EYE. SO I'M A BIG FAN OF YOU GUYS' SHOW AN ALL.

SO THAT'S DEFINITELY COOL. EVERYBODY'S GOT A SMALL BLOCK CHEVY AND STUFF, SO PRETTY NEAT.

(CHRIS)>> IT'S A LITTLE BIT DIFFERENT. EVERYONE'S PUTTING COYOTE MOTORS IN THEM AND I LIKE THE VSIX. YOU'RE GONNA GET A LITTLE BIT OF FUEL ECONOMY AND DRIVABILITY, AND GOOD HORSEPOWER. YOU'LL SURPRISE A FEW PEOPLE I THINK. ( )>> RESTO MOD, NOTHING WRONG WITH THAT AT ALL. IF YOU HAVE THE BUCKS TO DO IT IT'S VERY COOL, VERY, VERY COOL.

(PAT)>> THESE GUYS HAVE BEEN BUSTING THEIR BUTTS ON THIS AND IT LOOKS FANTASTIC, AND ALTHOUGH IT'S A LITTLE ON THE NOT DONE SIDE IT'S OKAY SHOWING PEOPLE WHAT IT'S GONNA BE, AND IT LOOKS GREAT.

(LT)>> WE'VE TEST FIRED THE ENGINE, WE KNOW EVERYTHING WORKS, IT'S JUST WE'RE STILL IN THE MIDDLE OF BUILDING IT. ANOTHER MONTH OR SO WE'LL BE DONE PROBABLY. ( )>> WOW, IT LOOKS WAY DIFFERENT IN THERE.

( )>> I LOVE THE CLEAN LINES AND THE CLEAN LOOK, AND I LOVE THE STEEL GRAY AND WHITE COMBINATION. IT'S GORGEOUS, AND IT'S SIMPLISTIC, BUT IT SHOWS ELEGANCE AND BEAUTY, AND A LOT OF PEOPLE THINK OLDER TRUCKS ARE KINDA LIKE BEEFY AND OUT DATED, AND I THINK THEY HAVE ELEGANCE THAT WE HAVE LOST IN CAR MANUFACTURING THESE DAYS,

AND THEY HAVE LIKE A BEAUTY AND CRAFTSMANSHIP THAT WE SHOULD LOOK BACK TO, AND HOPEFULLY IMPLEMENT INTO OUR VEHICLES OF THE FUTURE.

(NARRATOR)>> NEXT HOW TO CUT A CURVED WINDSHIELD.

(JEREMY)>> WE'RE BACK ON TRUCK TECH AND WE'RE FINALLY READY

TO GET SOME GLASS IN OUR F-100. NOW SINCE THIS IS A CURVED WINDSHIELD IT'S KIND OF A SPECIAL TASK TO BE ABLE TO CUT IT DOWN AND

NOT BREAK ANYTHING. SO WE CALLED GLASS GUY CHICAGO BRIAN HARDING TO COME IN AND HELP US OUT. MAN THANKS FOR COMING IN.

(BRIAN)>> NO PROBLEM, I'M REALLY EXCITED TO GET WORKING ON THIS TRUCK.

(JEREMY)>> THAT'S AWESOME. NOW BRIAN IS WELL KNOWN IN THE ENTERTAINMENT AND FILM INDUSTRY AND HE'S GOT A PRETTY COOL JOB. TELL US A LITTLE BIT ABOUT THAT.

(BRIAN)>> WELL I WORK ON SOME TV SHOWS IN CHICAGO, CHICAGO FIRE, CHICAGO PD, SOME OTHER SHOWS THAT COME TO TOWN, AND WHAT I DO IS I WORK WITH SPECIAL EFFECTS AND BASICALLY THEY'RE BLOWING UP WINDOWS, THEY'RE BLOWING OUT WINDSHIELDS, AND I TAKE A NEW PIECE AND I'M THERE FOR TAKE TWO.

I PUT A NEW PIECE IN FOR TAKE THREE UNTIL THEY GET THE SHOT.

(JEREMY)>> THAT SOUNDS LIKE A PRETTY COOL GIG.

(BRIAN)>> YEAH IT'S PRETTY COOL.

(JEREMY)>> NOW AS YOU GUYS KNOW OUR TRUCK CAME TO US ALREADY CHOPPED AND IT ALSO CAME WITH GLASS THAT WAS ALREADY CUT DOWN, AND WELL IT DIDN'T REALLY FIT TOO GOOD.

(BRIAN)>> NO, NO, WHEN SOMEBODY CHOPS A TOP ON A CAR,

WHETHER IT BE THIS TRUCK, AN OLD '50'S HOT ROD, JUST BECAUSE YOU CHOP IT THREE INCHES DOESN'T NECESSARY MEAN THE GLASS CHANGED THREE INCHES. SO THEY TOOK THREE INCHES OFF THE WINDSHIELD, AND AS YOU CAN SEE WHEN WE PUT IT IN WE CAN PUT OUR THROUGH IT. IT WAS A LITTLE SHORT. SO WHAT WE NEED TO DO IS WE'LL MAKE SOME NEW TEMPLATES AND WE'LL WALK PEOPLE HOW WE DO THAT, AND WE'LL GET IT CHOPPED AND GET IT IN THERE.

(JEREMY)>> LET'S DO IT, I'LL TRY NOT TO BREAK ANYTHING.

(BRIAN)>> THAT'S RIGHT. WE START BY PUTTING THE POSTER BOARD, OR CARDBOARD, ON THE OUTSIDE OF THE PINCH WELD OF THE TRUCK. WE'LL DRAW WITH A MARKER AROUND THE INSIDE OF THE PINCH WELD. WE THEN ADD TO THE TEMPLATE FOR THE PINCH WELD WHERE THE GLASS IS GONNA REST. IN THIS CASE IT ENDED UP BEING A QUARTER OF AN INCH. SO WE ADDED A QUARTER OF AN INCH TO OUR DAYLIGHT SIZE. WE TRIMMED OUT THE PATTERN, WE LAID THAT BACK IN THE TRUCK TO MAKE SURE THE GLASS IS GONNA LAY WHERE WE WANT IT TO. AFTER WE'RE DONE AND WE HAVE THAT SET THE WAY WE WANT, WE TRANSFER IT TO THE GLASS, WE LAY OUR LINE ON THE GLASS, AND WE'RE READY TO CUT.

(JEREMY)>> SO WHAT DO YOU USE TO CUT THE GLASS WITH?

(BRIAN)>> WE USE A GLASS CUTTER, AND IT'S A LITTLE DIFFERENT THAN ONE YOU WOULD GET DOWN THE STREET AT YOUR HARDWARE STORE.

(JEREMY)>> I'M CURIOUS, I WANT TO SEE THIS THING.

(BRIAN)>> SO THE KIND I USE IS SELF OILING. SO THIS KEEPS OIL ON THE WHEEL. THE WHEEL IS A DIAMOND WHEEL, WHICH IS WHAT BREAKS THE SURFACE TENSION OF THE GLASS, GETS IT TO BREAK.

(JEREMY)>> SO WHEN YOU START CUTTING ABOUT HOW DEEP DOES IT CUT INTO THE GLASS?

(BRIAN)>> IT'S VERY, VERY MINOR. ALL YOU'RE DOING IS BREAKING THE SURFACE TENSION OF THE GLASS, AND WE'RE RUNNING IT, WHICH MEANS WE'RE FORCING THE GLASS TO CRACK WHERE WE RAN THE GLASS CUTTER.

(JEREMY)>> ABOUT HOW MUCH PRESSURE DOES THAT TAKE WHEN YOU'RE LAYING DOWN?

(BRIAN)>> IT TAKES A LITTLE BIT MORE THAN YOU WOULD BE WITH A MARKER OR A PENCIL WHEN YOU'RE WRITING. WHEN I CUT THE CORNERS OFF OF THE GLASS IT TAKES AWAY A STRESS POINT IN THE CORNER, WHICH IS WHAT WE CALL A "CUP".

IT'S WHERE THE WINDOW IN THE CORNER, THE CURVE GOES TWO DIFFERENT DIRECTIONS IN THE CORNER.

SO WE CLIP THAT OFF TO ELIMINATE A STRESS POINT FOR THE WINDSHIELD TO CRACK.

(JEREMY)>> YEAH THAT'S COOL! THAT'S A CLEAN CUT TOO, LOOK AT THAT.

(BRIAN)>> CALL THAT EXPERIENCE.

(JEREMY)>> THAT'S AWESOME.

(BRIAN)>> WHAT I'M GOING TO DO NOW IS I'M GOING TO DIVIDE UP THE AREA THAT WE'RE CUTTING OFF INTO TWO SECTIONS TO MAKE IT EASIER TO GET THE GLASS TO DO WHAT I WANT IT TO DO. EASIER TO WORK WITH AND ESSENTIALLY YOU TRY TO AVOID THE WINDSHIELD CRACKING WITH TOO MUCH STRESS. UNFORTUNATELY IT'S GLASS AND IT DOESN'T MATTER IF IT'S FLAT OR CURVED WINDOWS, GLASS HAS A MIND OF ITS OWN. IF IT DECIDES THAT IT WANTS TO CRACK IT'LL CRACK. THERE COULD BE A BUBBLE IN THE GLASS, THERE COULD BE AN IMPERFECTION IN THE EDGE. MY SUCCESS RATE AS FAR AS CURVED WINDSHIELDS GO, I'M USUALLY ABOUT 90 PERCENT OUT OF ALL OF THEM THAT I'VE CUT, AND HOPEFULLY THIS ISN'T ONE OF THEM THAT PUTS ME BELOW THAT AVERAGE. AFTER I RUN MY CUTTER WE'LL OPEN UP THE CUT, STARTING AT

EACH CORNER, TO GIVE THE GLASS A STARTING AND FINISHING POINT. YOU'RE ESSENTIALLY CRACKING THE GLASS WHERE I MADE THE CUT. WE'LL FLIP IT OVER.

WE'RE GONNA MAKE THE EXACT SAME CUT ON THE BACK SIDE. WHEN WE HAVE IT COMPLETELY RUN FROM END TO END I'LL PUT SOME DENATURED ALCOHOL ON IT. THE PROCESS OF DOING THIS IS TO HELP MELT OR SOFTEN THE LAMINATE BETWEEN THE GLASS TO HELP ME GET THAT CUT OFF THE GLASS. MOST CARS NOW HAVE TEMPERED SIDE WINDOWS. SO WHEN THEY BREAK THEY EXPLODE. A WINDSHIELD, WHEN YOU GET HIT BY A ROCK, IT CRACKS, AND THAT LAMINATE IN THE MIDDLE PROTECTS YOU INSIDE THE CAR, ESSENTIALLY KEEPING YOU SAFE FROM ANYTHING THAT HITS THE WINDSHIELD. IF I'M CUTTING ON SOMETHING THAT'S REALLY RARE, HARD TO GET, IT'S A LITTLE NERVE RACKING BECAUSE AGAIN, IT'S GLASS. SO WE HAVE A TENDENCY TO TAKE A LITTLE BIT MORE TIME AND SLOW IT DOWN A LITTLE BIT TO GET OUR CUTS RIGHT. NOW THAT WE HAVE THE FINAL PIECE OFF THE GLASS, WE'RE GONNA START WITH OUR FINISHING PROCESS. THE FINISHING PROCESS OF GLASS IS EXACTLY LIKE THE FINISHING

PROCESS OF PAINTING A CAR. IT'S STARTS AT 40 GRIT AND GOES ALL THE WAY UP TO 600 GRIT, AND YOU CAN EVEN POLISH IT WITH CORK AT THE END. ONCE WE'VE FINISHED WITH THE 220 GRIT, WE'RE HAPPY WITH THE SHAPE, WE'RE GONNA TEST FIT THE WINDOW IN THE TRUCK TO MAKE SURE IT STILL FITS. IF I NEED TO TRIM ANY CORNERS, I NEED TO ROUND ANY EDGES, WE NEED TO SHAVE DOWN A SIDE BECAUSE MAYBE THE POST MOVED, WE CAN DO THAT BEFORE WE'RE READY TO PUT IT IN THE TRUCK.

(JEREMY)>> THE PIECE IS TEST FIT ONE LAST TIME, AND THEN THE GASKET IS INSTALLED AROUND THE PINCH WELD JUST TO GET IT DOWN TO SIZE.

REMEMBER THE TWO INCH CHOP MEANS A SMALLER SEAL AROUND THE SMALLER GLASS. ONCE IT'S CUT, BRIAN WILL GLUE IT BACK TOGETHER, INSTALL IT

ON THE WINDSHIELD, AND THREAD IN THE WINDSHIELD ROPE. THEN THE WHOLE THING IS INSTALLED FROM THE OUTSIDE IN. REMOVING THE ROPE FORCES THE GASKET OUT OVER THE PINCH

WELD, AND A LITTLE AMMONIA FREE CLEANER HELPS MASSAGE THE GASKET IN PLACE.

YOU GOT IT MAN, IT'S IN.

(BRIAN)>> AWESOME!

(JEREMY)>> LOOKS GOOD, RUBBER SEATED WELL EVERYWHERE.

(NARRATOR)>> AHEAD JEREMY TRIES HIS HAND.

(JEREMY)>> ALRIGHT WE'VE GOT THE WINDSHIELD IN ON THE F-100 AFTER BRIAN HARDING, OWNER OF GLASS GUY CHICAGO, CUT ABOUT

TWO AND A HALF INCHES OUT OF A FACTORY PIECE TO ACCOMMODATE OUR CHOP, AND WHILE HE WAS DOING THAT I FIGURED OUT A WAY TO GET OUR DOOR GLASS TO WORK. IF YOU'LL REMEMBER, SEVERAL HANDS TOUCHED THIS TRUCK BEFORE LT AND I TOOK IT OVER, AND IT LOOKS LIKE THEY ATTEMPTED TO RUN POWER WINDOWS, BUT AFTER LOOKING AROUND THE SHOP ABOUT HALF THE PARTS WERE MISSING. NOW YOU WOULD THINK IT WOULD BE EASIER HAVING HALF THE WORK

ALREADY DONE FOR YOU BUT FOR ME IT'S THE OPPOSITE. I WOULD MUCH RATHER START A PROJECT THAN TRY TO FINISH SOMEONE ELSE'S, BUT WHAT ARE YOU GONNA DO? FROM THE FACTORY OUR F-100 DOOR GLASS WAS ACTUALLY TWO PIECES. A VENT WINDOW UP FRONT AND MAIN GLASS BEHIND IT. NOW WE WANT TO GET RID OF ALL THAT AND INSTALL A ONE PIECE GLASS KIT. IT'S A MUCH CLEANER LOOK AND A VERY POPULAR HOT RODDER UPGRADE. THE PROBLEM IS IF YOU DO A SEARCH ONLINE FOR A '55 F-100

ONE PIECE GLASS KIT YOU WON'T FIND MANY OPTIONS. SO WE DECIDED TO MAKE OUR OWN AND IT'S PRETTY SIMPLE TO DO. NOW FOR THE FRONT CHANNEL WHERE WE WANT THE WINDOW TO GUIDE UP AND DOWN I'M ACTUALLY USING A FACTORY PIECE THAT DIVIDED THE VENT GLASS AND THE MAIN GLASS. NOW FOR THE CHANNEL THAT RUNS AROUND THE DOOR WE PICKED UP SOME UNIVERSAL STUFF AND BENT IT TO SHAPE. NOW AS IT RUNS DOWN THE DOOR IT RUNS INTO THE FACTORY CHANNEL. NOW FOR THE REGULATOR AND THE LIFT CHANNEL, ALSO FACTORY PARTS FROM THE F-100. NOW THE ONLY PROBLEM WE RAN INTO WHEN WE GOT IT IN THE

DOOR IS THAT THE FRONT CHANNEL KICKED IN A LITTLE TOO MUCH, WHICH MEANS THE GLASS WOULD HAVE LAID AGAINST THE REGULATOR, PROBABLY BEEN IMPOSSIBLE TO ROLL UP AND DOWN, AND WOULDN'T TAKE MUCH TO SHATTER IT. SO THE BRACKET THAT MOUNTS TO THE DOOR, I CUT IT IN HALF AND EXTENDED IT AN INCH. THAT'LL LINE EVERYTHING UP SO THE WINDOW WILL ROLL UP AND DOWN NICELY. SO FOR A ONE PIECE WINDOW KIT WE WERE ABLE TO USE ALL FACTORY PARTS WE HAD LAYING AROUND THE SHOP.

ALL WE NEED TO DO NOW IS CUT A LITTLE GLASS. FIRST BRIAN WILL TAKE CARE OF THE BACK WINDOW GLASS ON THE FORD USING THE SAME PROCESS AS THE WINDSHIELD. A CARDBOARD TEMPLATE IS USED FOR THE PATTERN.

THEN HE'LL CAREFULLY USE HIS GLASS CUTTER TO RUN MULTIPLE LINES ON BOTH SIDES TO GET THE PIECE DOWN TO A MANAGEABLE SIZE. IF HE CUT RIGHT ALONG THE TEMPLATE LINES TO START THERE'S A BETTER CHANCE FOR HIS CUTS TO RUN THE WRONG WAY, WHICH FOR ANY GLASS GUY IS A DISASTER. BRIAN'S USED TO THE PRESSURE.

(BRIAN)>> ALRIGHT, HERE WE GO.

(JEREMY)>> OUR TEAM BROUGHT HIM IN ABOUT FOUR YEARS BACK TO CUT PANE ON A CHOPPED '51 HUDSON HORNET COUPE. THE WICKED CURVE WAS NO MATCH FOR THIS SHY BOY'S TALENTS.

(BRIAN)>> AND THAT'S HOW YOU CUT A CURVED WINDSHIELD.

(JEREMY)>> AND LAST YEAR THE TWO PIECE ON THIS '49 FORD WAS LESS OF A PAIN, BUT STILL REQUIRED THE STEADY HAND NEEDED TO GET THE JOB DONE RIGHT. SINCE THE BACK WINDOW OF OUR FORD IS FLAT, IT'S WAY EASIER TO CUT THAN THE CURVED WINDSHIELD. AGAIN, STRAIGHT LINE CUTS WILL GET IT TO SIZE, AND THEN ONCE THE EDGES ARE TRIMMED BRIAN WILL GRIND AND SEAM THE EDGES OF THE BACK GLASS TO MATCH THE TEMPLATE PERFECTLY. WITH THE GASKET IN PLACE, THE WINDOW INSTALLS FROM THE INSIDE OUT, AND NO GLUE OR CLIPS HOLD IT IN PLACE. THE GASKET LIPS OVER THE OUTSIDE PINCH WELD, MAKING IT PERMANENTLY SECURE, AND NOW WE CAN MOVE ON TO CUTTING DOOR GLASS. YOU MAKE THIS GLASS STUFF LOOK PRETTY EASY.

(BRIAN)>> WELL WHY DON'T YOU GIVE IT A TRY?

(JEREMY)>> OH CRAP, HOW MUCH GLASS DID YOU BRING?

(BRIAN)>> WE'VE GOT PLENTY.

(JEREMY)>> SO I CAN BREAK ONE AND WE'RE GOOD.

(BRIAN)>> YOU CAN BREAK ONE, WE'RE GOOD. SO LET'S START, LET'S TAKE THIS CORNER OFF.

(JEREMY)>> OKAY, LET'S SEE.

(BRIAN)>> IT'S KINDA LIKE PIN STRIPPING.

(JEREMY)>> IT DOESN'T MATTER THAT I'M A LITTLE SHAKY?

(BRIAN)>> NAH, YOU'RE GOOD.

(JEREMY)>> I PULL STRAIGHT LINES WHEN I PIN STRIPE.

(BRIAN)>> THAT'S PERFECT.

(JEREMY)>> HERE WE GO.

GET ON THERE.

(BRIAN)>> SLOW AND STEADY.

SO NOW LET'S MOVE IT OFF THE TABLE SO WE CAN OPEN UP OUR CUT.

TAKE YOUR HAND AND YOU'RE GONNA FORCE THIS DOWN TO OPEN THAT UP.

(JEREMY)>> JUST A LITTLE PRESSURE?

(BRIAN)>> JUST A LITTLE PRESSURE, NOT A LOT OF PRESSURE.

(JEREMY)>> I GOT THAT OPEN, I DIDN'T SEE IT.

(BRIAN)>> I SAW IT SHOOT THROUGH THERE. SO YOU CAN JUST KINDA KEEP GOING AND YOU'RE ALL THE WAY TO THE SIDE.

(JEREMY)>> NOW I'LL FLIP IT OVER AND MAKE THE SECOND CUT ALONG THE SAME LINE. THEN PULL DOWN TO GET YOUR RUN.

(BRIAN)>> GOOD NEWS IS...

(JEREMY)>> IT WENT THE OTHER WAY.

(BRIAN)>> ALL THE CRACKS WENT THE GOOD WAY. SO NOW WE SHOULD BE LOOSE.

(JEREMY)>> MAN YOU'VE GOT ME SWEATING OVER HERE. I'VE ONLY MADE ONE CUT, I'M SOAKING WET.

(BRIAN)>> IT'S NOT AS EASY AS IT LOOKS IS IT?

(JEREMY)>> WELL NOW I KNOW WHAT NOT TO DO.

I'LL JUST FOLLOW THE SAME PROCESS ON ALL THE OTHER CUTS. YEAH IT'S FUN TO TRY SOMETHING NEW, BUT IN THE 40 MINUTES IT TOOK ME TO CUT THIS ONE DOOR GLASS, WELL AS BRIAN JUST

SAID, THAT CRACKED ME UP. I THINK I'LL LEAVE THE GLASS CUTTING TO THE EXPERTS. WELL THAT ABOUT DOES IT. HOW DO YOU THINK I DID?

(BRIAN)>> THIS WILL BE THE MOMENT OF TRUTH.

(JEREMY)>> LET'S CHECK IT OUT.

(BRIAN)>> I'D SAY YOU DID PRETTY GOOD.

(JEREMY)>> THAT'S NOT TOO BAD. WELL THAT COMES FROM HAVING A GOOD TEACHER RIGHT?

(BRIAN)>> I APPRECIATE THAT.

(JEREMY)>> WELL WE REALLY WANT TO THANK GLASS GUY CHICAGO BRIAN HARDING FOR COMING IN AND CUTTING ALL

THE GLASS FOR OUR F-100. THE TRUCK LOOKS AWESOME AND MAN, HOPE TO HAVE YOU BACK AGAIN SOME TIME.

(BRIAN)>> I'M A PHONE CALL AWAY.

(NARRATOR)>> NEXT, PEDAL POWER!

(LT)>> ONE OF THE MORE IMPORTANT THINGS WE HAVE LEFT TO INSTALL ON OUR FORD ARE THE PEDALS. ORIGINALLY THEY WOULD BE MOUNTED ON THE FRAME BELOW THE

FLOOR BOARD, BUT THERE'S A LOT OF THINGS THAT WE HAVE CHANGED

SINCE 1955 THAT WILL PREVENT US FROM USING THE ORIGINAL STYLE PEDALS. FOR ONE, THIS TRUCK WAS ORIGINALLY EQUIPPED WITH FOUR WHEEL DRUM BRAKES, AND WE'VE SWAPPED THOSE OUT FOR FOUR WHEEL DISCS. SO THE BRAKE MASTER CYLINDER WILL NO LONGER WORK FOR US. AND NUMBER, THE TRANSMISSION WE INSTALLED USES A HYDRAULIC THROW OUT BEARING INSTEAD OF A MECHANICAL LINKAGE. SO WE'D HAVE TO DO A LITTLE BIT OF FABRICATION TO GET THOSE TWO TO ADAPT TOGETHER. NOW LUCKILY FOR US THERE'S A LOT OF OPTIONS ON THE AFTERMARKET THAT HELP US UPGRADE BRAKES ON THESE CLASSIC AMERICAN TRUCKS. TAKE OUR C-10 FOR EXAMPLE. IT'S A HEAVY FULL SIZE TRUCK WITH A BIG POWER PLANT. SO TO GO ALONG WITH THAT WE NEED A LOT OF STOPPING POWER. SO WE INSTALLED A HYDROBOOST. IT MOUNTS IN THE TRUCK BETWEEN THE MASTER CYLINDER AND THE BRAKE PEDAL, AND USES HYDRAULIC PRESSURE FROM THE POWER STEERING SYSTEM.

THE FLUID STARTS AT THE PUMP AND RUNS FIRST

TO THE HYDROBOOST. IT THEN GOES BACK DOWN TO THE STEERING GEAR BOX AND THEN RETURNS TO THE PUMP. NOW THIS BRAKING SYSTEM ALSO USES A PROPORTIONING VALVE. THIS SENDS MORE BRAKING PRESSURE TO THE FRONT WHEELS THAN IT DOES TO THE REAR SO YOU DON'T LOCK THEM UP UNDER HEAVY BRAKING CONDITIONS. HYDROBOOST BRAKES WORK VERY WELL. YOU GET AMAZING STOPPING POWER WITH VERY LITTLE PEDAL EFFORT, BUT UNFORTUNATELY FOR US THAT THREEFIVE ECOBOOST JUST DOESN'T HAVE A PLACE TO MOUNT THE POWER STEERING PUMP. SO THAT OPTION'S OUT THE WINDOW. WE COULD HOWEVER MOUNT A VACUUM BOOSTER. THESE THINGS HAVE BEEN AROUND FOR DECADES, AND INSTEAD OF POWER STEERING FLUID THEY USE YOUR ENGINE'S VACUUM TO PROVIDE THE ASSISTANCE.

NOW THESE THINGS ARE KIND OF BULKY.

IT'S OFTEN HARD TO FIND A PLACE TO MOUNT THEM

PROPERLY ON THE FIREWALL. NOT ONLY THAT, THEY'RE PRETTY UGLY TO LOOK AT, EVEN IF THEY ARE CHROME PLATED. SO WE WENT TO SUMMIT RACING AND PICKED UP A PAIR OF THESE PEDAL AND MASTER CYLINDER ASSEMBLIES. AND AFTER TALKING TO THE MANUFACTURER, WE DECIDED TO RUN THESE WITHOUT ANY BOOSTERS AT ALL. BY PROPERLY SIZING THE MASTER CYLINDERS AT POINT EIGHTEIGHT BORE FOR THE FRONT AND POINT EIGHTONE ON THE REAR WE'LL HAVE AMAZING STOPPING POWER. AND INSTEAD OF A PROPORTIONING VALVE THIS PEDAL INCLUDES A BALANCE BAR. THIS ALLOWS US TO ADJUST THE BIAS OF THE BRAKES FROM FRONT TO REAR, ONCE AGAIN SO WE DON'T LOCK UP THE BACK TIRES UNDER HEAVY BRAKING.

FOR THE CLUTCH PEDAL WE CHOSE A SEPARATE ONE SO WE CAN SPACE

IT OUT IN BETWEEN THE STEERING COLUMN, AND THIS ONE RUNS A POINT SEVENFIVE BORE, SLIGHTLY SMALLER THAN THE REST. THE COOL THING ABOUT THIS STYLE OF BRAKE PEDAL IS YOU CAN ACTUALLY USE A REMOTE FLUID RESERVOIR, OR YOU CAN MOUNT IT DIRECTLY TO THE MASTER CYLINDER LIKE WE'RE GOING TO DO, AND THE FIRST THING WE'RE GONNA DO IS MAKE SOME HOLES IN JEREMY'S BRAND NEW PAINT JOB. THAT MAKES ME HAPPY. THIS SETUP PROVIDES A LOT MORE FLEXIBILITY IN WHERE YOU PLACE

THE PEDAL ASSEMBLIES, ESPECIALLY SINCE YOU DON'T HAVE TO WORRY ABOUT CLEARANCE FOR A BULKY VACUUM BOOSTER. LUCKILY THERE IS A REINFORCEMENT BAR RUNNING

UNDERNEATH THE DASHBOARD, AND ALL I HAVE TO DO IS MAKE TWO SHORT BRACES TO ATTACH TO THE FRONT OF THE DASH. I'LL MAKE SOME LARGER HOLES IN THE FIREWALL AND DEBURR THE EDGES. HANG THE PEDAL ASSEMBLY, MOUNT THE MASTER CYLINDERS, AND TIGHTEN IT ALL DOWN TO DRILL THE LAST TWO HOLES. CRAWL ON THE BOOT AND THREAD THE RODS INTO THE BALANCE BAR, AND A FOOT PAD IS THE ICING ON THE CAKE. DO THE SAME THING WITH THE CLUTCH PEDAL, WE'LL BE GOOD TO GO.

(JEREMY)>> WELL LT IT LOOKS LIKE WE CAN MARK A COUPLE OF MORE THINGS OFF OF THIS LIST. I GOT THE BED BOLTED TOGETHER, YOU GOT THE BRAKE PEDAL IN, AND WE'VE MADE A PRETTY GOOD DENT IN THIS LIST AND WE REALLY DON'T HAVE A LOT LEFT.

(LT)>> YOU KNOW THERE'S BEEN A LOT OF LATE NIGHTS AND A LOT OF BEHIND THE SCENES WORK TO GET THE TRUCK WHERE IT IS TODAY, AND THE NEXT TIME YOU GUYS SEE IT WE'LL BE OUT ON THE ROAD LISTENING TO THOSE TURBOS SPOOL UP.

(JEREMY)>> MAN I CAN'T WAIT TO DRIVE IT, BUT FOR TODAY LET'S GET OUT OF HERE.