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My 2004 Super duty needs new cab corners and rockers. I bought all the sheet metal and should have all the tools needed. I have never done this before just figure I need to take mt time, any advice? What size holes should I make for the new spot/plug welds on the panels, 5/16". Anyone what to help? LOL
1/4" holes should be more than enough. Use weld through primer and seam sealer where needed and you should be fine!
Something to consider with the rockers, and i have never done this but the local auto shop supply house should be able to tell you ..... IMHO I would also look at panel bond (glue) in place of welding for the rockers... I know it's used extensively on the new cars and used in structural areas as well.
I'll give you a hand if you can get the truck to me. I have the tools and a hoist.
Thank you for the offer. I also have all the tools needed. If you where closer I might take you up on that. I am located in Denver, NC a little far from you. Thank you
I agree: <=1/4" holes for plug welds. make some test welds, of course, You might even want 3/16 depending on the steel the panels are made from, what wire and gas, and such.
I used a spot weld cutter drill bit worked great on the rockers, cab corners and the firewall that I swapped into my truck.
I used a air powered hole punch to put holes in the above panels and the floors for plug welding, also worked great.
I did 2 coats of seam sealer. First was from a gun to force it into any gaps and the second was brush on to cover the first and look factory.
Both sides were done like this.
What you do if you want factory AC
Just take your time
Dave ----
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