How much of this cab corner would you cut out and repair?

 

Push hard on any/all dark spots, pits with a sharp awl. When it stops going thru, cut a little above. If you are using a patch panel, don't be afraid to cut back as far as necessary to get into sound metal hopefully staying within the area of the patch panel.

 

Basically what Ax said. You want to make your cut in good sound rust free metal to weld to.

 

I poked hard with sharp punch. This is all I got. I don't wanna cut anymore than I have to. If I make small cut, how do I spray rust eliminator up in there to get it all?

 

It looks like some nice solid metal there, overall. If you have to make a patch, size doesn't matter too much. I'd make a hole large enough that you can clean out the valley from dirt, debris and scale, then weld in the patch and coat the entire valley pocket on the inside with your favorite rust converter stuff.

 

I did my cab corners and yep exactly what Ax said

 

I cut enough out of my cab corners to allow me to sandblast inside. On the driver's side I had intended to eliminate the gas filler anyway so I cut out more than would be needed if the gas filler is kept. I shot weld thru primer on all of the inside sandblasted areas before I installed the new cab corners.







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I've installed several sets of cab corners and I don't think you really save much time on the repair by trying to keep it small especially if you have some rust lurking above where you've probed and it shows up later after you have that nice paint job.

 

Thx drewski. Did u use 025 or 030 wire? I wanna get rid of the gas filler hole also. That pic you showed of your patch piece is a good example of how I wanna do mine. Thx for showing.. Merry Xmas!!

 

Why? Looks like about the bottom 3-4" needs to be removed and the structure behind it checked/repaired as needed before refacing the skin. I will guarantee there is structural damage behind that area.

 

Well, like usual I went all out crazy. I'll post more pics under my build thread. Didn't look bad behind cab corner. Wanted to get rid of the gas filler hole.

 

And this fell out in the beginning...

 

Ha ha! The things you find! In an old Buick I had a while back it had about ten packets of cookies in their wraps and a handful of fliers letting everyone know about a church service being held soon... in 1963.
I'll be there is some guy out there now looking at that and thinking... "so THAT is where I lost it!"

 

I use 030 wire. I used to switch back and forth between 023 and 030. I stopped doing that a long time ago, finding that I could do everything that I typically work on with 030. I think one of our members (MP&C) uses 035 wire and his work is top notch. I guess it depends on what you get used to.

I welded a plate over the gas filler hole and seam sealed it on both sides before I installed the new cab corner.

 

For sheet metal repair I prefer .023 wire. It welds at lower heat so it helps with warpage IMHO.