Videos: 10 Common Mistakes in Restoring Classic Ford Pickups 1957-1991

Restoring a 1957–1991 Ford pickup isn’t just a project - it’s a rite of passage. These trucks were born tough, worked hard, and survived decades of abuse, rust, and questionable “fixes” by shade-tree mechanics. Bringing one back from the dead is equal parts glory and headache and trust me — there are a few potholes you don’t want to hit along the way.

Here are the top 10 mistakes that’ll separate the weekend dreamers from the diehard wrench-turners. Avoid these, and your F-100 or F-150 will look good, drive better, and earn you that approving nod at the next cars-and-coffee.

1. Rust: The Silent Killer

Above: Rather rusty but restorable 1965 Ford F100 (photo courtesy of Ford Muscle - a Power AutoMedia online magazine) - lead photo is of a 1962 Ford F100 restomod (photo courtesy of Mecum Auctions)

If you think “a little surface rust” is no big deal, guess again. These trucks rot in sneaky places: cab corners, floor pans, and the frame near the rear spring hangers. Too many people slap on some filler and paint, only to watch their pride and joy bubble up again a year later.

Pro move: Hunt down rust like it owes you money. Cut it out, weld it right, and seal it up for good.

2. Polishing a Pig: Neglecting the Frame

Above: 1977 Ford F250 4X4 with a frame that's built Ford tough and restored to shiny and tough (photo courtesy of Mecum Auctions)

Here’s the hard truth: no one cares how shiny your paint is if your truck drives like a shopping cart. Worn bushings, sloppy steering boxes, and sagging leaf springs will make your ride feel like it belongs back on the farm.

Pro move: Drop the frame, blast it, coat it, and rebuild the suspension. A Ford that tracks straight down the highway? That’s sexy.

3. Bargain-Bin Parts

Sure, you could save a buck with that paper-thin repop, but when the bolt holes don’t line up and the door gap looks like the Grand Canyon, you’ll wish you’d spent the extra cash.

Pro move: Stick to OEM or high-quality repros. Hunt swap meets. Scour junkyards. Quality parts are worth the chase.

Above and below: OER Premier 1967-72 Ford F100, F250, F350 pickup hood assembly comprised of stamped steel - premium quality - part # TR16612LB

4. Franken-Truck Drivetrains

Big-block dreams are cool — until you realize your radiator can’t cool it, your trans can’t handle it, and your gears turn highway cruising into a 3,500 RPM scream fest.

Pro move: Build the drivetrain as a team. Engine, transmission, cooling, and gears should play nice together, not fight like toddlers in the backseat.

Above: ATK Engines Ford V8 high performance crate engine - Stage 3 Complete Ford Stroker V8 408/480HP/500TQ - part # 408ENG

Above: Should you enjoy going through the gears yourself, a good option may well be a Tremec TKX five-speed manual transmission for your Ford hot rod hauler - part # TCET18086 - American Powertrain.

5. Wiring Nightmares

Nothing ruins the thrill of a first start like smoke curling out from under the dash. Reusing 40-year-old brittle wiring or twisting in mystery splices is a recipe for frustration (and maybe flames).

Pro move: Yank it all. Replace the harness. Add solid grounds and relays. Think of wiring as the nervous system of your truck — you want it sharp, not sketchy.

6. Skipping the Dirty Work Before Paint

Everyone loves a shiny paint job. But paint over bad prep and you’ll be crying when the fisheyes, cracks, and chips show up six months later. Even worse? Spraying first and then realizing your panels don’t line up.

Pro move: Block-sand like your life depends on it. Dry fit everything before paint. Remember: prep is 90% of the finish.

Video: How to Paint Classic Truck - DIY Paint Removal, Metal Prep, Primer Options and Paint Application - Busted Classic Garage

7. Brake Amnesia

Let’s be real: factory drum brakes on a 4,000-pound truck weren’t great in the ’70s, and they’re terrifying now. Don’t be that guy who builds a beast of an engine but leaves the brakes in 1965.

Pro move: Rebuild or upgrade. Disc conversions are cheap insurance — for you and everyone else on the road.

Above and below: This 1963 Ford F100 restomod has four wheel disc brakes and lots of other refinements (photo courtesy of Mecum Auctions):

• 1,750 miles since built
• Magnaflow exhaust
• Heidts front end
• 1999 Explorer 8.8 Tri-Bar Rear
• RideTech Air Ride
• Two Airmaxx compressors
• Wilwood 12-Inch, 4-piston disc brakes
• Ridler 20-inch 650 wheels
• Nitto 245-40R20/ 315-35 R20
• 1957 big back window
• Power windows
• Single pane side glass
• Drip moldings removed
• Third brake light
• Bumpers removed front and rear
• 1964 smoothed bed  
• Tailgate welded shut
• Fiberglass tonneau cover
• Custom rear pan
• Zephyr taillights
• Custom front end
• 1966 F100 chrome grille
• LED Headlights
• House of Kolor Ultra Orange Pearl
• Interior

8. Getting the Interior Wrong

The devil’s in the details. Too many builds end up with carpet that doesn’t fit, seat covers from the wrong year, or AutoZone gauges that look out of place. A mismatched interior screams “almost finished.”

Pro move: Research your year. Get the right trim or commit to a tasteful custom vibe. Don’t half-step it.

Above: The interior of the 1963 Ford F100 restomod is as killer as the exterior.

9. Over-Restoring (a.k.a. Killing the Soul)

These trucks weren’t born to be pampered showpieces. Stripping every ounce of character and loading up on billet parts can make your Ford look more like a SEMA display than a truck. Sometimes, a little patina tells the better story.

Pro move: Decide up front: do you want a show queen, a weekend warrior, or a daily cruiser? Let the truck’s history guide you.

Above: 1966 Ford F100 done just right (another Mecum Auctions photo)

10. Forgetting to Document the Journey

You will forget where that bag of bolts goes. And when it’s time to sell, nothing builds buyer confidence like a fat stack of photos and receipts. Documentation isn’t just for bragging rights — it’s for your sanity.

Pro move: Bag and tag everything, take photos at every step, and keep a build binder. Future-you will send past-you a thank-you thirst-quenching, ice cold beverage. You can also document everything with photography and video. Check out this restoration video below, documenting renewing a 1965 Ford F100 and converting it from a long bed to a short bed hot rod fleetside hauler. Hot diggity dog!

Video: Restoring a 1965 Ford F100 - Be Restored

Final Lap

Restoring a Ford pickup isn’t about making it perfect - it’s about making it yours. Avoid these common mistakes, and you’ll end up with a truck that drives better, looks sharper, and carries its history with pride. After all, these Fords were built tough - you’re just giving them a second shot at life.