56 Cab Corners
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Senior User
Joined: Sep 2003
Posts: 113
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From: Grant Park Il.
56 Cab Corners
How difficult is it to weld in new cab corners? Who makes the best replacement sheet metal? I would like to do this myself but have never welded in body panels before. Are they typically mig welded in? thanks for the help. 
Post Fiend
Joined: Feb 2001
Posts: 6,328
Likes: 124
From: Iowa
midfifty.com among many other places. They also sell some parts on this website in the "Parts Shop" on the upper right of this screen.
MIG or TIG are the usual installation methods. MIG being much more affordable for the average builder. Get one that is at least upgradable to Argon. Some of the guys here use flux core. I prefer gas by a wide margin. Cab corner install isn't too bad. It's a good second project maybe. Start by fixing some smaller blems in places that don't show. After a short while, you'll get comfortable, and you'll fully understand the necessity of trimming a patch panel for a good tight seam before you tackle the corners.
MIG or TIG are the usual installation methods. MIG being much more affordable for the average builder. Get one that is at least upgradable to Argon. Some of the guys here use flux core. I prefer gas by a wide margin. Cab corner install isn't too bad. It's a good second project maybe. Start by fixing some smaller blems in places that don't show. After a short while, you'll get comfortable, and you'll fully understand the necessity of trimming a patch panel for a good tight seam before you tackle the corners.
Postmaster
Joined: Jun 2004
Posts: 4,190
Likes: 2
From: Riverside, So Cal
F100man - What Fatfenders said.
Cab corners aren't too bad. I am new to welding and bought an inexpensive MIG setup that has really turned out great. In my gallery, I have pictures of the hood repair I did recently. It was similar (in contour, etc) to what you're talking about.
The most important info that I have found out about welding sheet metal is:
1. Fit the patch panel very well. Bevel prep butt weld edges with a small (.040) gap between pieces for weld penetration.
2. Do the actual welding by using tack welds, cooling each after it is applied using air or a wet cloth. Jump around the patch periphery with the welds until the whole seam is filled. Take it slow. Check the fit as you go (it will move some - you can hammer/dolly the patch back flush if it moves). Keep the heat down - too much heat into the work warps the pieces.
3. Grind the welds smooth and flush. Take this slow too. Don't lay on the grinder too hard - that puts a lot of heat into the work too.
4. No matter how crappy a welder you are, the grinding makes it all look swell.
5. Body filler is God's gift to amateur weld fabbers.
Definately do this yourself! It is just the most fun and satisfying work that I have done on my Effie.
My two cents.
Cab corners aren't too bad. I am new to welding and bought an inexpensive MIG setup that has really turned out great. In my gallery, I have pictures of the hood repair I did recently. It was similar (in contour, etc) to what you're talking about.
The most important info that I have found out about welding sheet metal is:
1. Fit the patch panel very well. Bevel prep butt weld edges with a small (.040) gap between pieces for weld penetration.
2. Do the actual welding by using tack welds, cooling each after it is applied using air or a wet cloth. Jump around the patch periphery with the welds until the whole seam is filled. Take it slow. Check the fit as you go (it will move some - you can hammer/dolly the patch back flush if it moves). Keep the heat down - too much heat into the work warps the pieces.
3. Grind the welds smooth and flush. Take this slow too. Don't lay on the grinder too hard - that puts a lot of heat into the work too.
4. No matter how crappy a welder you are, the grinding makes it all look swell.
5. Body filler is God's gift to amateur weld fabbers.
Definately do this yourself! It is just the most fun and satisfying work that I have done on my Effie.
My two cents.
Last edited by Randy Jack; Dec 3, 2004 at 09:40 AM.
Post Fiend
Joined: Feb 2001
Posts: 6,328
Likes: 124
From: Iowa
"1. Fit the patch panel very well. Bevel prep butt weld edges with a small (.040) gap between pieces for weld penetration."
Excellent guidance from RandyJack. He figured it out fast. For every minute you spend fitting the patch correctly, you will be repaid by one minute less of grinder sparks bouncing off your chest, and two minutes of sniffing bondo dust. Not to mention the repair will have a better chance of lasting longer.
I use a bit less than .040 gap for less chance of blowing holes, but .040 does seem to be the number I see thrown around by the pros. They must weld better than me.
Excellent guidance from RandyJack. He figured it out fast. For every minute you spend fitting the patch correctly, you will be repaid by one minute less of grinder sparks bouncing off your chest, and two minutes of sniffing bondo dust. Not to mention the repair will have a better chance of lasting longer.
I use a bit less than .040 gap for less chance of blowing holes, but .040 does seem to be the number I see thrown around by the pros. They must weld better than me.
Posting Guru
Joined: Apr 2004
Posts: 1,074
Likes: 0
From: Northwestern PA
F100, Have to agree with Fenders and Randy, This is a doable project for beginers. But do take the time to get use to the welder (Mig w/gas best in my opinion). I think getting the old corner off is harder than putting the new on, those darn spot welds can be a pain. Just takes time. Also as Randy said, a butt weld will do a better job for ya in the end.
And Welcome to FTE there is alot of valueable info here as well as support.
Mike
And Welcome to FTE there is alot of valueable info here as well as support.
Mike
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Senior User
Joined: Sep 2003
Posts: 113
Likes: 2
From: Grant Park Il.
cab corners
Thanks for all the info guys - I have a good mig welder and am a pretty good welder -- i am just worried about cutting the old one out the right way. I really want to tackle this myself so ill just have to have a free weekend and go for it. I sure appreciate all the advise.
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