Re: 72 C10 Build
 

Yep, you guessed it, more sanding. Here’s a bed pic showing all the mud on that right door skin in the background.

Re: 72 C10 Build
 

Did I mention the right lower rear cab area is not good? :waah: He's a lumpy baby! :lol:

Re: 72 C10 Build
 

A little more cutting, the floor patches will be pretty big. The goal is to hide the repairs as much as possible, especially the underside. Fingers crossed! :lol:

Re: 72 C10 Build
 

Nice work, I'm knee deep in cab floor replacement too! United in misery...

Re: 72 C10 Build
 

JMO but it would be easier to remove the reinforcement plate so you can attach the out rigger part. Under the plate is a tube that is hard to get out b/c of the sides of the outrigger are in the way, so it is easier to cut them out of your way now and you have access to the flanges of the out rigger

Also, I prefer to go to the factory seam at the forward edge as there is a prebent 90 in this area, makes for an easier weld
Also I have a high hump so it was better to cut to that flange to hid the seam

Make sure you don’t get the slip on out riggers as they are junk……

Nice work so far enjoy the build

https://live.staticflickr.com/65535/...dd117a7a_c.jpgimage by [url=https://www.flickr.com/photos/202110214@N03

Re: 72 C10 Build
 

https://live.staticflickr.com/65535/...4f174776_c.jpgimage by [url=https://www.flickr.com/photos/97391199@N06

Re: 72 C10 Build
 

Thanks Roger, so true. If you want to build one of these trucks you will most likely have some rust issues to deal with. Ha, I say that and the very next truck I bought had no rust, just a small hole in the back, my 72 K30 Build.

Thanks Jim, in hindsight we (my boy & I) could have done things differently for sure. I agree with you on taking it to the pinch weld area and the cab mount anti-crush sleeve deals were in good shape. Also, as I mentioned earlier if this was happening today it certainly would’ve gotten a new floor assembly. You know, I did enjoy this time with my son very much.



Same-ol’ just a little more cutting. Working the cab corners and getting after the left rear cab support. Right rear support for some reason is solid (corner of the cab with the most accident damage :confused:).

Dateline update: These pics are dated 12/25/2011 so at this point we’ve had the project about 6 months.

Re: 72 C10 Build
 

The core support is good enough to go again. The only area that needed any attention was right under the battery tray. Got this patch panel from Brothers at the time, and it looks like it’s still available from Holley. It's a pretty straightforward install, cut to fit, clean, and weld. :ito:

Re: 72 C10 Build
 

Lots of cab patch panels have arrived. We also scored this nice original automatic high hump and some miscellaneous bits from a fellow forum member. In addition, I grabbed some reproduction fenders as well as some other stuff from a local body supply store. The fenders we have are not bad but these were a very good deal, we’ll see if they make it onto the truck or not.

Re: 72 C10 Build
 

Back to the right door, parts are here and the outer skin is removed. Also, I received a premade patch for the gas tank filler hole and a heater block-off kit. The plan is that the truck will get aftermarket AC at some point. :cool:

Re: 72 C10 Build
 

We had a nickel-sized rust hole in the bed floor that I mentioned earlier. I missed getting a before pic but, here are a couple of the first repair passes. Wasn’t 100% sure how far we'd go with the right inner door shell repair. I only used a small part of that large inner patch panel to repair the rusted-out area. With the skin removed it gave us good access to both sides of the patch. Also, allowing the straightening of the lower and rear door shell areas. If you recall that rear area was pretty wavy from the earlier accident. :ito:

Re: 72 C10 Build
 

Here are a few after welding up the rust repair.

Re: 72 C10 Build
 

I have lots of similar rust locations. Keep chugging along

Re: 72 C10 Build
 

Thanks, will do. My boys and I are having a good time on this one. ;)


Right inner rocker fitment and a quick check of the lower fender mount spec I took earlier (7.5” ish). That green stuff is Eastwood Internal Frame Coating, I sprayed up in the roof and both A & B pillars. I figured it couldn’t hurt and may slow the rust.

Re: 72 C10 Build
 

Sub'd to follow along with the rest of the build. Nice progress so far on the rust repairs. I just went through all the same issues last year.

Re: 72 C10 Build
 

Thanks, I appreciate it. Ha, more to come. We tore right into it.



After fitting the right front cab support, we started welding up the inner rocker on that side.

Re: 72 C10 Build
 

Welding up the right front cab support. HF copper spoon just fits in the support channel.

Re: 72 C10 Build
 

Metal work is going great! It's a frustrating but satisfying process.

Re: 72 C10 Build
 

Thanks Roger, it's cool to see it start coming back together.



Left inner rocker fitment and opening the floor up for better access to the rear support on this side. Before and after getting a small patch ready for the toe board.

Re: 72 C10 Build
 

Here’s some right inner rocker and kick panel welding. Followed by lower a-pillar fitment. It’s moving right along….. :ito:

Re: 72 C10 Build
 

Back to the left side, the inner rocker is going in to help hold the rear cab support in place for the final fit and weld. The kick panel, toe patch, and support have all gone in on this side. :)

Even started working the right cab corner a little more by fitting the lower b-pillar/door jamb.

Re: 72 C10 Build
 

Here are the backside shots of these patches. Final fitment of the left rear cab support prior to weld, I’m pleased with how this is turning out.

The lower right a-pillar is done, and our right floor pan patch is ready to go! :ww:

Re: 72 C10 Build
 

Great work