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ok,I will try to explain this best I can. on the top of the bed sides where it goes into the roll is there an easy way to straighten these out without replacing the bedsides????
I don't think so. What might work, in theory, is if you heat the area bright red and stick a metal tube inside the whole all the way through. This might help to straighten the area. You'll need to finish it with some body filler.
Another way is to shape it with body filler or build up welds in the area and grind smooth.
Here's my idea; Make a couple of different diameter pieces of steel rods, with both ends ground to a dull point, about 3-4 inches long. The first just a little larger than smallest dent and push it through with a slightly smaller steel rod. Once you're able to send it through without a problem use a larger diameter plug and progress until you have the dents worked out. If you have some particularly bad dents you could have some one heat the area with a torch while pushing the bullet through.
By using a plug you have less of a chance of getting a full length of steel rod stuck in the tube and also you will only need short pieces of different diameter rod. You don't want the plug too short to decrease the possibility of having the bullet getting cocked in the tube. The double point would make it easier to push back if it gets stuck.
I have cut the rolls off completely and welded on 1-1/4 tubing in its place. If you have the tools and skillset then this is a clean way to fix a number of issues with the top rails.
I have cut the rolls off completely and welded on 1-1/4 tubing in its place. If you have the tools and skillset then this is a clean way to fix a number of issues with the top rails.
That's what I did on my F-2, I used black water pipe with the same OD as the original tube. I also beveled the ends a little to knock down the thickness so they looked more like stock. The black pipe will never dent unless you drop some massive weight on it.
Mine was pretty beat up too. So I'm just going to make some new sides and save the hassle. The metal I'm using for the sides is going to cost me just over $100 for the pair. And since I plan to use the box for hauling stuff I'm going to use some heavier wall tubing for the top roll. Then just weld it to the new box sides.
I was thinking about just cutting out the section that was bad and welding a new piece in. Seems like that would be easier than replacing the whole tube.
One thing about these old trucks Mal is you can have it your way. I think the best way is to if your not sure ask for advice and pick the way you want to do it. If you do weld just take your time and don,t wrap the metal.
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