96 ext cab corners

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Oct 16, 2007 | 10:28 AM

wildcat99

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96 ext cab corners

I'm thinking about fixing the cab corners myself. This is the worst one with rust about 24-in long. Patch panels are 21-in long or they have the complete cab corner that wraps around the back. Should I get 2 panels and piece together to make one long enough or just get the whole corner?

I'm also planning to use adhesive. I'm looking for an air nibbler to cut it out and a flange tool. I've never done any of this before so I would appreciate any suggestions, maybe a rough step-by-step and what other tools/supplies are needed.

Rivets, no rivets, drill-out rivets??? I believe Eastwood has a kit with steel rivets and a dimple tool for both panels and the rivets get left in. Is this a good idea or will they loosen up over time? Aluminum rivets would be easy enough to drill out after the adhesive has set, but what do you do with all the holes?

Thanks for all your suggestions!

Oct 17, 2007 | 12:50 PM

wildcat99

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I understand how the flange tool works to give you a recess for the patch panel to fit flush, but what do you do with the sides? Will the flanger work over the contours? Also what do you do where the sides meet the bottom edge?

Has anyone repaired a cab corner this bad? How did it turn out?

Everything is sound on this truck except for the rust. Fenders and the bed are replaceable easy enough if needed, but these cab corners have me worried. If I let it go much longer I'm afraid it will start doing structural damage and the door won't close right, etc.

Should I just get a new truck?

Oct 17, 2007 | 01:56 PM

cujo8

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From: Williamson, NY

Check out my WebShot photos of how I repaired my cab corners and feel free to ask questions.

Oct 17, 2007 | 11:42 PM

wildcat99

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Very nice project truck. Just looking at everything you've done motivates me to get these corners fixed. Not looking for show quality...anything I do has to look better!

After closer look I can get complete corners end-to-end so I don't have to worry about blending in side seams. Once I get parts/tools and get started I will definitely have more questions. Thanks

Oct 18, 2007 | 06:35 AM

cujo8

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From: Williamson, NY

Quote:

Originally Posted by wildcat99

After closer look I can get complete corners end-to-end so I don't have to worry about blending in side seams. Once I get parts/tools and get started I will definitely have more questions. Thanks

One word of advice, even though you can get complete cab corner patch panels only use as much of the panel as you need to make the repair. Also, be prepared to massage the patch panel to make it fit properly. I had to cut/remove metal from my patch panel to make them fit properly, but this was still much easier than forming the cab corner by hand.