Thought I would share another update of my sheet metal work.
The right floor pan is in, and toe board patched.
Cowl patch tacked in place, and I had to make a lower 'cap'.
The kick panel and lower cab corner needed patches as well.
Also had to fix the seat/under floor re-inforcements, as the right side was worn badly.

 

Very nice work! Do you have a sheet metal brake? Those are clean bends.

For the door post repair, on the cap that seals the bottom; there was a flap kind of drain on the stock piece to let water that leaked past the windshield out. Don't weld it up solid, looks like water could get out at the corners.

 

Nice work

I'm curious as well, how did you manage to make such nice bends?

Bobby

 

Good timing. I need the same kind of repair and was thinking of how to do it. Your pics make it look easy. Glad you posted them.

 

Thanks. The bends were a combination of vise, anvil and pliers.

When I fabbed the lower 'cap', I did leave small gaps for drainage. The original was mostly gone, so I couldnt tell for sure, but I figured there should be drainage.
This is the template I made from the remainder of the cap pieces. I will just reverse it for the other side. (its not exact, but a little tweaking afterwards worked pretty well.

 

Man I'm glad I remembered this thread. I need to make the same little cardboard pattern for that cap. I tried to make that cap tonight, and it looks like a wadded up soda can. That's very neat work. Did you go back and put a drain hole (or tab) in it?

 

Hi Doc
Once it is welded in place, there are small 'gaps' just like the original.
If you want, shoot me a pm with your address, and I can send you a copy of the pattern

 

Thanks! PM sent.

 

This is a prime example of what attracted me to this forum Help,Co-operation and freely sharing ideas and information as well as being generally enjoyable.
Thanks

 

I did almost the same exact patch as yours chriscris. I still need the inner cap. My concern with it. When enough dust/moisture accumulates, will it clog the small gaps?
I am going to make mine like the original ones. A three sided square tab cut to let water out. The tab opening dumps to the rear of the truck to allow a draft to help pull moisture out while driving. I wonder how well that really worked, but the idea is pretty cool. On mine there was alot of buildup down in there, and thats where my concern is. I left it open for now, but need to get that done eventually. Nice work!

 

I suppose over time, if enough stuff were to get in there, it could clog, but it is only open to the inside of the cab, so 'theoretically' it should be OK. I tried to make it as close to original, and used 18ga (probably overkill 20 should suffice)

here is the left one, tweaked and ready to get some holes drilled for plug welds.

 

Man that is a nice patch!