Hi guys. Been posting over in the Engine Swap section. I thought the paint and bodywork section would be more appropriate for this.

Picked up a pretty rusty Crew Cab a few months back. Decided to swap in a Cummins. That's done now I'm on to Cab bodywork.

After tearing into this thing i realized it had a pretty bad resto job. Lot's of lead fill, bondo and rivets...

Here's the pics. I'm sure there's some pro's out there so any advice is welcome.

Here ya go...

Here's what I started with





Roof could be peeled off like tuna can. (Going to be putting a Ford Econoline corrugated roof on eventually)



Floor was held together by galvanized sheet metal and rivets, oh and some silicone ha ha



So I cut out all the bad metal and ordered my replacement panels.



Inner and Outer Rocker panels removed



Here's everything coming back together



This part has no repair panels available so this is strictly sheet metal work. I intend to have this look exactly like OE when finished.

I am using a 4.5" angle grinder, a 30" Brake from Harbor Freight, Hobart Handler 120 MIG and basic body tools here. Cleco's are a lifesaver to hold things in place.

 

Looking good so far.....clecos are definatly good helper to have. I used to use small zip screws (still do on occasion) but when you have to keep taking off then putting back on the panel they make life easier.
If you have air, you might want to look at getting a angle die grinder with a 2" pad for Roloc pads to help with the welds though. Then you can use 26 grit sand paper to knock them down without all the extra heat a grinder brings. 1/4" Front Exhaust Air Angle Die Grinder - Grinders - Air Tools

 

Thanks,

I have the craftsman version with the 2" pads.

My problem is the compressor only pushes 6CFM so it puts quite a strain on my weekend warrior.

Miss my dual stage I had 10 years ago. Used to paint cars in the garage with that bad boy.

I use 36 grit like you said to keep warpage down. 22 ga steel kinda flexy.

Anyway this weekend making a parts run to pick up a '78 single cab, doghouse, and shortbed I picked up for $500.

The nice thing about these crews is they used many of the same panels the singles cabs did (except the middle section). I can use this as a donor to fix my cab.

 

Nice work...are you going to modify reg cab parts for the outer rockers?

I'm not even sure if thats possible but it sounds like a good solution.

 

The inner rocker is slightly different but the outer rocker is exactly the same.

The seam will be covered by the lower rear panel.

There is no good rocker repair panels that are as strong as the originals.

But in looking at the crew and standard cab you can see where there is basically a seam and they added a center section of floor to extend the cab. Up to this point they are the same.

The rear part of the crew is the same as the rear of the standard cab again the only difference being a seam where they joined the 2.

Almost done with the repair I'll be posting pics soon.

 

Looking good! You are doing some nice work.

 

Looks good.


Love the old crews.

 

I got some OEM outer rockers from Green Sales last summer if you need them.

 

Thanks,

I have 2 from my parts truck ill be getting to the rear doors soon. I'll let you know.

I need rear doors of anybody has an idea where some are available.

 

Anymore pictures from this restoration?

 

I have a nice rear door w no rust, but has a dent. Need to get it out of the garage.

 

How much for the door?

 

message me and we can figure something out

 

Well guys judging by the last time i posted its been a few years.

This little guy was a year and a half old when this whole thing started.



He starts kindergarten in 4 months. Yikes..

As with most of these projects the work took priority over posting.

Here's the update.

It's now at the painters getting final block sand and sealer.

Should have color by the end of the month.

Here are the pics so far.

 

A fellow poster suggested it would have been easier to buy a scrap cab and start from scratch.

In hindsight i would have to agree.

It took a donor cab, a metal fabricator, and a bunch of reproduction sheetmetal to get this cab like it is here.



It is probably 50% original sheetmetal.