cab corners, rocker, and floor.. and then....

[blazin454]

so im pretty new to welding but ive been practicing alot and i am pretty happy with my progress... im about to weld (or attemp) in new cab corners rocker panel and a floor pan into my 76 stepside.... the truck is a mess but i will have fun trying to get it all back together i will try to post pics... after that ive got an 88 blazer the flooring is good all the way back as well as inner fenders but the outers are a mess around the rear wheel wells and mostly the passenger side... im going to try to attempt to do that as well... any advice? or do i just measure (or trace) cut out and patch? any help on the "proper procedure" would be appreaciated... thanks to all for the help in advance...

[whateg0]

Pick up some scrap sheetmetal to practice on. Use 0.023" solid wire and shielding gas. I don't think body panels are good for starting out with flux-core. Weld small sections and skip around a lot to keep the heat from building up too much.

Good luck!

Dave

[blazin454]

right on thanks alot..... ive got some old panels to practictice on now too so hopefully i dont mangle anything lol

[Hotfoot]

Try You Tube, and enter "Auto Body",.Cab Corners", 'Body Panel", etc. there are lots of really good auto body repair clips on there!:)

[Jaxom]

Glad this was brought up. This past spring I was extremely busy with a temp job at a nusery. Few weeks ago I was laid off (sigh), but unemployment should be kicking any day now. Even though it's mid july, I'm hoping to get some work done on my Chevy S-10.

While I have managed to get some mechanical stuff done, the body is a nightmare to look at. I belong to a chevy S-10 website and did some reading on body work and how to fix panels. But I haven't gotten too much advice in welding.

Several of the sticky authors on this site recommend to fix or fill large rust holes is to weld on some sheet metal as a patch behind the hole, before welding in more sheet to fill the hole. Further more they also recommend after all the welding and sanding is done is to hit up the hidden patch with some rust preventer or such.

That all makes sence if you can get at the back side of some of the holes. But what if you can't? One place that would be very difficult for me to get at right now is the front corners of the bed, right behind the cab. I'm not ready to put this vehicle up on blocks and pull the bed off just to get at these spots, but there's gotta be someway I can fix that up somewhat.

For places where I can buy pre formed replacement bits, what's the best way to cut away the rusted out spots? I've got a grinder already, but would sheers or a nibbler be better?

While I'm thinking of it. I do have a few mechnical things that could use some heat to expedite getting them done. Besides, it's an excuse to buy more welding gear (as if we need one! LOL). Having working on my brakes this morning and seeing how badly I need shocks and how rusty they are, I've been tossing around the idea of getting one of those small oxy/act rigs with a cutting torch. What's a good price for one of these portable jobs and which brands are good? I see alot of oxy/acet stuff on craigslist, but I'm leary about getting stuck with tanks that can't be certified and be out the cash. And finally how much does it usually cost to fill both tanks?

Thanks

Jax

[blazin454]

from what i read you are asking if there is any other way to do cab corners other than taking the box off to get into the tight spots right? if so there isnt any that i know of i have done one cab corner but it was years ago lol... if i remember right we had the box off... but it really isnt very tough at all to take a box off or at least move it back a little to give yourself some room... you and one other buddy could hand bomb a box easily im sure... as for my stepside... i was gonna buy the cab corners rocker panel and a floor pan but i think i might just bend up my own floor pan.... as for putting them in you can either overlap slightly or butt up the two pieces right? some prefere to overlap some dont what do you guys think? i would like to just butt the pieces up to one another but was told it can be very difficult to do

[Jaxom]

Actually it's the bed corners that I've got an issue with. Cab wise the major issues is below the door. Plan for me is...is to just stop the bleeding for now. Ideally I want to put the truck up on blocks and do a complete restoration/engine rebuild. But since I live in a snow/road salt area, I want to do something so I don't end up having to buy a whole new body peice meal.

I know I already have to get two new front fenders, driver's side door and tailgate.

Wish I could watch You Tube, blasted sound card died on me. Watching online video's without sound is like reading a book with only nouns in it.

Sidebar: Unlike alot of folks I've met online I don't have much experience with mechianics and or body work. Only what I learned while a teen, before all my friends married and moved away. I've been watching some sales on ebay. Do service manuals go into detail on how to repair a vehicles body? I definetly need something with more detail then your average haynes/chilton's book.

Jax

[greywynd]

I know I already have to get two new front fenders, driver's side door and tailgate.
Jax

So....there's where you start. Pick one that you're going to replace anyway, and try your hand at the body work on it first. Get into the rusted area(s) weld in the patches, and give it a skim of filler and primer. If you can get results you're happy with, then you learned something, and if not, well, you're not out a whole lot at that point.

[blazin454]

after all said and done you will be re painting it right? you can try what i tried... not too far from where i live ther is an autobody shop and i talked to the guy about teaching me when he has free time and then it would be me doing all the prep and patch work ect. and he would only be spraying it.. he agreed so i now have someone to show me and give me good hints and tips and i also get a good deal on the paint job lol....

[Ferntj]

That all makes sence if you can get at the back side of some of the holes. But what if you can't?

You can drill holes around the edge of the hole you made when you cut out the rusted area. Then make strips of sheet metal about 2 inches wide to go around the repair area. Clamp the strips behind the body panel and keyhole weld the strip to the body through the holes you drilled. Now you have a backing plate to hold your repair patch against and to hepl keep you from blowing holes in the body and repair panel when you weld the seem.

[blazin454]

You can drill holes around the edge of the hole you made when you cut out the rusted area. Then make strips of sheet metal about 2 inches wide to go around the repair area. Clamp the strips behind the body panel and keyhole weld the strip to the body through the holes you drilled. Now you have a backing plate to hold your repair patch against and to hepl keep you from blowing holes in the body and repair panel when you weld the seem.

i like that idea. i was wondering how i could rig up some kinda backing plate and i think that will work great on my box sides especially

[whateg0]

You should make sure you use some sort of weld-thru primer or seal the edges well if the 'backing-strip' is on the exterior, as it's a good place to trap moisture.

just my 2¢

Dave

[COMP]

You should make sure you use some sort of weld-thru primer or seal the edges well if the 'backing-strip' is on the exterior, as it's a good place to trap moisture.

just my 2¢

Dave

good reminder

[whateg0]

That's what I like about butt welds. No places for moisture to get trapped.

Dave

[Jaxom]

As always, excellent advice! I like the idea of the backing plate and filer holes.

Although, now that I've looked it over and thought about this a while. I think I'm just going to replace the whole left and right side skin of the bed. There's just so much rust it wouldn't be worth the time to fix all that either rusted through or will blow through once I sand blast it.

Although I cannot watch youtube videos, or any other videos for that matter since my sound card died, but I have read more on doing body parts. About the only other question I have, since many of the truck forums have a wide range of thoughts on this is.... What's the best wire for doing body work?

[Sberry]

I would be tempted to toss the bed and make something??? Look at the cross members for sure, if there was any load in this they crush. I am leery of restore work anymore, I fix a few things if I have to but would consider a southern vacation and buy something I didn't have to patch extensively. It is a good learning process though, usually you learn (I ain't never doing that again) ha.

[Jaxom]

The bed its self is pretty solid. Although the tailgate is pretty much shot, and the left and right outside panels have rusted badly. Luckly someone was smart enough to put a liner in the truck. I took a peek under it and then crawled up into the bed and tapped around a bit, and it's pretty solid.

I know I'm going to have to pull the entire bed off the truck, it's listing towards the rear bumper slightly. I think this is mainly due to the front brakets that bolt to the panels and frame have nothing to hold onto at the panel and have rusted through. But I won't know for sure until I pull it off.

[CarNut]

There's a good thread on the Tri-Five Chevy forum that I'm on. The consensus seems to be that butt welding is much better than lap for body panels but there are always a few guys who prefer the lap welds.

Anyway, the following address will take you to a good discussion about panel welding.

By the way, on that forum I am not ChevyNut. There's another one.

Gerry
http://www.trifive.com/forums/showthread.php?t=2313

[whateg0]

There's a good thread on the Tri-Five Chevy forum that I'm on. The consensus seems to be that butt welding is much better than lap for body panels but there are always a few guys who prefer the lap welds.

Anyway, the following address will take you to a good discussion about panel welding.

By the way, on that forum I am not ChevyNut. There's another one.

Gerry
http://www.trifive.com/forums/showthread.php?t=2313

Especially on classics and such, a lot of people prefer butt welds because it allows the panel to be metalfinished. Kinda hard to do with multiple layers.

Dave

[92f150300six]

when i do body panels i reall like to weld in a 2 inch strip all the way around the piece i cut out makes it so much eazyer to get the panel to sit nice and flat.but where i do things diffrent i use .035 flux core wire that way i dont have to swap out wire from when i do diffrent projects.