I picked up a new project this past summer. I've been working on it for a month or so. After blasting the cab, things looked worse than I had hoped for. I have to replace all the floors and corners and a lot of the support structure. I used the common patches and had to make a number of my own.

I'm not using any complicated tools, besides a TIG. And I'm only tigging for practice. I'm a hobbiest and want to show that anyone, with time, can do this. I mainly form pieces with hammers over shapes around the shop, like a gas cylinder cap, a broom stick, edge of my bench, etc.

I'll post some before/after photos here. In some case I might show some more detailed shots. Hopefully it can be of help to someone.

 

 

 

 

With all that rot you are getting lots of experience, and it looks good! Yours makes me feel really lucky, I only had to replace the transmission cover and patch a few small areas. No corners and no structural pieces at all.

 

You da man Wdglide! That is some extensive rebuild. If you dont have the skill sets now, you will. I am learning to weld with my Miller 211 mig. I have the replacement floor pan for the driver side and need to repair the lower fender edges and running boards mounting points. You inspire me.

 

Looking good!

Be sure to document where you get your sheet metal pieces from, be cool to have a book from the truck that shows people you're door actually has a piece of a tool box or something welded in it.

 

Thanks.

I have a parts truck that I got for the chassis. It had no floors at all in the cab. After replacing the entire floor and four corners, I may no longer consider that one a "parts" truck.

My point of this thread is that no special (expensive) tools are needed. Anyone with the time and commitment can do this.

 

Wdglide
That looks like zinc chromate.

 

Wow, Nice work. I'm following along.

 

Its self etching primer. I'm just hitting the areas that will be impossible to get to later.

 

Very wise wdglide.
I thought this was a interesting website

Roadkill Customs - Hot Rods, Rat Rods, Custom Cars and Trucks

 

Here's a video of the rotisserie I made for the cab. Its made with a few 2x4's and some 3/4" black pipe I had lying around. The brace across the door is unistrut. This allowed me to move the center point to the weighted center.

 

Just about done with the floors and corners. I have it back on the chassis and the doors are pretty close.

Here's the rot I removed...

 

I admire your skills. Thanks for sharing.