i am replacing the cab corners on a 1983 f-100 and don't know the first thing about what i'm doing. i have a wire welder and a cutoff tool and wish to do this on my own.(what fun is having a 4x4 if you don't do some of the work?) help please......all help appreciated.

 

Welcome to FTE.

If you'll do a search of this forum and check out the "Patch Panel/Rust Repair" thread at the top of this forum, you'll find all the information you're looking for.

 

I would suggest 2 things before you start.
1. Buy this tool. It will make removing the spot welds sooo much easier. https://www.ford-trucks.com/user_gal...=13092&width=1
2. Practice welding on some scrap metal. Get your heat and wire settings right because once you start blowing holes, you will get frustrated very quickly.

 

This is procedure that has worked but bear in mind that all vehicles and years are not put together the same and you may have to adjust this prodcedure to make it work for you.

The first thing I would do is take the ‘New’ cab corner and lay it over the corner you will be cutting out. Mark the top of the new corner on your truck with a marker and then remark the ‘old’ panel about 1” below that new mark. This will insure you don’t take out too much panel until the fit can be better marked. I would also suggest getting the tool mentioned by Krosati. Take that tool and drill out the spot welds that are holding only the part of the panel you plan to cut out.

When you drill out the spot, you will drill all the way through the spot (both inner and outer panel) with just the ‘Tip’ of the tool. Then drill through only the top panel with the shoulder of the tool (not all the way through both panels).

Once all the spots have been drilled, take a flat chisel, air chisel or flat screwdriver etc… to separate the panels. When the outer panel has been removed, clean up the inner areas of any rust and prime it with a good weld through primer.

Now you need to determine which method to use in welding in the new panel. Most prefer the butt weld, others like to over lap and some will create a flange in the old panel and set the new panel over it (similar to a lap weld) and MIG weld it in.

Now position and clamp the new corner into the new position, and now mark the top of the new panel onto the old panel and scribe a mark. Now if you butt weld cut it at that mark, if you lap or flange weld, mark about ¼” to ½” below the mark and cut.

Prep the back of the new panel with the same weld through primer. Weld in the panel, take precautions not to get it too hot causing warping in the sheet metal. See this post for the technique. https://www.ford-trucks.com/forums/s...threadid=82480

Then MIG weld the up the spot welds. One other thing to consider is the cab corners come in a specific length, but you don’t have to install the complete panel. If a smaller section is bad, simply cut the new panel down, then proceed with your marking and installation.

 

If by chance you also need the lower (rear) part of the door jamb area, it too is available from the aftermarket. You need to do it while the cab corner is out of the way. I just did my 86 since it was rotted out where the seat belt anchor bolt goes in. So was part of the door sill area, but you can make that out of sheetmetal. (it's available too though) Good luck,