[Steve91T]

I've been putting these off for years and I think it's time to take care of them before they get bad.


https://flic.kr/p/Wum5ch

https://flic.kr/p/VRBKWn


Ok, there might be a chance I've waited too long.

I've called several body shops and they either don't want to do it or want $1k for the pair. Since I want to weld up my new exhaust anyway, I figured I'd learn to weld and do the corners as well. I've read they can be a bitch because of the thin sheet metal. Also I'll probably have to slide the bed back to give me room.

The inner skin is gone, not sure how to fix that. I figured this would be a good excuse to dip the interior out of the truck, replace seals, shift boot and Dynamat the floor.
The other side isn't as bad but it's getting there.

What do you guys think? Learn to weld on my exhaust then try to corners?

[trackbird]

My friend wants me to do the ones on his (the "worst case" truck I mention). One secret is a pneumatic flanging tool from Harbor freight. It will form a "step" into the existing metal to let you lay the new cab corner in place (cut it out leaving about 3/8" of material on the inside...give or take). Once you flange it, you can drop the cab corner in place and weld with metal behind the weld. That's far easier than edge welding panels together. Also, use .023 wire in the mig welder. You'll have better control and better results. Beads are hard to grind off, don't weld them too tall, you'll destroy the metal trying to grind the weld down. You're better to add some bondo and smooth it instead of welding it too tall and trying to grind it smooth.