I bought my new corners from LMC and the two sides that were hardest to line up was the door pillar and the rib on the back of the cab. The replacement has a little different profile on these two areas so they required massaging.
If it were mine i wouldn't cut out the pillar or cut through the rib. Only replace the very bottom where rusted through. Patch fitment is a big issue with every vendor.

 

I'll be following along, I am getting ready to do the same. Looks like you already replaced the rocker?

 

Haven't started on rockers. They are only rusted at each end about 2 inch worth. The worst part on the truck will be the roof drip rail area.

 

That's what I was thinking. I bought the patch panels about 8 years ago and a quick fit check tells me massaging will be required.

 

If it were me, I would remove the outer -- all the way around -- but only high enough to allow you access to your inner corner repair.

I would handle that large hole you cut as a separate job.

Mine was worse than yours, but I did a similar repair recently (see link in my signature).

 

My cab was worse than yours! Take a look at my albums....I took a lot of pics as I was doing the metal work on the cab. Might be of some help.


I had no metal working experience before I started, but really enjoyed doing it once I started.

 

Dennis Carpenter & MidFifty both have new steel roofs for 56s. After buying 2 additional donor roofs and having them both sand blasted I’d have been money ahead to have bought the new steel roof.

 

Thanks all for advice. My Mig just broke (lowest setting won't work) once I get this repaired it's time to dive in and make some sparks

 

When you get to the point of tacking your corners in, let me suggest you hang a door(you can use visegrip clamps to hold it while you get everything aligned) that way you can see just what you've got in door gap and adjust accordingly.

 

I did the dumb thing.........and cut the whole corner off. Then tried to massage an entire new corner on. PITA. They still aren't right........Rear indent is wrong, door opening is wrong, curvature is wrong..


If I'd had mine to do over, I still would have removed a large chunk of the corner (very carefully). Replaced my inner corners, blasted the old outer corners, patched them up and welded them back in.