Re: 1968 C10 Stepside Restoration Project
 

Thanks! There are still flaws, but I will work on them. Most folks probably wouldn't notice, except those well versed in these trucks.

Re: 1968 C10 Stepside Restoration Project
 

More progress made. O cleaned up the body work around the passenger side kick panel/inner cowl. I also finished the rockers and did the block sanding around the cab corners and back panel of the cab addition, I started the refinement of the seams in the passenger side door jamb.

Re: 1968 C10 Stepside Restoration Project
 

There is still a dent along the lower portion of the cab near the left passenger cab corner. I will straighten out this area and a small depression I discovered while block sanding.. I will also do more work on smoothing out the door jamb seams on the passenger side.

In addition to that I applied more Rust Mort through the cabin light opening and sun visor holes. I will use the spray gun with the flexible hoze/nozzle to get further into the cavity above the roof headliner.

Re: 1968 C10 Stepside Restoration Project
 

I also picked up a little accessory for the truck, a vintage Fyr Fyter extinguisher to mount in the cab.

Re: 1968 C10 Stepside Restoration Project
 

After a bit, maybe more than a bit, of cleaning, here is the fire extinguisher now. Cool thing is, you can recharge this at home by refilling and repressurizing this particular model. Not bad for a $13 purchase.

I also picked up this Ray-O-vac flashlight for the truck as well.

Re: 1968 C10 Stepside Restoration Project
 

Cool finds! Those will be awesome to have in there.

Re: 1968 C10 Stepside Restoration Project
 

So this week I have been on Jury Duty, so I have not been working on the truck as much during the week in the evenings. I have been sanding and trying to work out some minor dings and dents. Seems I keep finding more as I block sand the cab, but all-in-all it is looking good.

Re: 1968 C10 Stepside Restoration Project
 

Forgot the pics...

Re: 1968 C10 Stepside Restoration Project
 

Looking excellent! :clap:

Re: 1968 C10 Stepside Restoration Project
 

It really is turning out nice and smooth, wish I had the patients to do any type of body work.

Re: 1968 C10 Stepside Restoration Project
 

Great build, keep up the hard work. Keep on truckin'' :metal:

Re: 1968 C10 Stepside Restoration Project
 

Thanks Trucknut57 and RCbowtie69!

In all seriousness, I attribute my body work abilities to all those hours in my youth building model airplanes. With models, you have to use putty to hide seams and then you have to sand everything to get a good surface to paint. This truck is just a bit on a larger scale, but the same principle.

Re: 1968 C10 Stepside Restoration Project
 

Looking GREAT! Nice job!
I am in about the same place as you with my "66.... I have the major body rust and dents fixed so far and now it is in Epoxy sealer and now I am doing the minor dents and guide coats. long long process but when it is done, you will be very happy!!

Re: 1968 C10 Stepside Restoration Project
 

I have one little bit of work to do before I epoxy prime the interior of the cab. This is that area inside the cab that is opposite of the cowl drainage area. For some reason that side rusted badly, the passenger side not at all.

Not sure why the photo is upside down, but you can see that this will be a challenge being where it is.

Re: 1968 C10 Stepside Restoration Project
 

So today was a good day, did a little welding to patch a hole below the vent on the driver's side and got the dents out on the cab just below the gas filler opening on the corner of the cab.

Re: 1968 C10 Stepside Restoration Project
 

That is really a weird place for rust if you ask me. I have seen it in alot of other places, places I just fixed, but not sure i have ever seen it here. At least it is fixable and not really visible to everyone.
I plan to coat the entire inside of the cab floor, dash wall and behind the dash and such with Por 15. I bought 3 quarts some time ago from Summit, it showed up with one having a slight puking episode and got all over the other 2. I called summit and they just sent me 3 more, so now i have 5+ quarts so i will do all the inside in it, cowl area, and such for protection.
It is great to watch someone build their ride at about the same place i am. I am not doing much right now to mine due to our heat being well over 100 here for the next 5 days or so, with Monday being over 110! ya, i have AC in shop but not enough to correct that heat... so i am watching others build theirs for a week or so ... lol

Re: 1968 C10 Stepside Restoration Project
 

I saw where Portland is expecting 112 degrees today, I do not envy you being up there in that extreme of heat. Stay cool, stay inside!

I think there was debris in the cowl area that retained moisture over the 15 or so years this truck sat outside idle. I believe I vacuumed all that out trying to make sure I got all the mouse nests out when I did the initial cleaning before I tore everything apart.

I will be using one of the old inner fenders to make patch panels - the inner fender has the curved shape needed to somewhat closely rebuild that area of the truck.

I will be coating the inside of the cowl with Raptor Liner to prevent any repeat of rust.

Re: 1968 C10 Stepside Restoration Project
 

So the welding repair of the kick panel is complete and I have ground down the welds. A little skim coat of filler and primer to see how it is turning out.

Just need to clean-up around the vent opening.

Re: 1968 C10 Stepside Restoration Project
 

Looks great sir!
I had to repair the exact same area in my "66. I got it looking good and then I built Speaker Pods that will cover this area and use the old Fresh air intake as a sound chamber. I also bought a flat Cowl cover (no vents) as i also have Vintage Air kit.

The heat really sucks. We are used to it being warm, but this is just nuts. Even with the AC in the shop, it is still just too hot to paint. I will be trying to install my "paint booth" this 4th of July and be ready to start painting later in July when it calms down a bit. May be painting at 4am but oh well... I guess it will be like have a heat box to dry the paint... LOL

Re: 1968 C10 Stepside Restoration Project
 

Some BEFORE and AFTER shots.

Re: 1968 C10 Stepside Restoration Project
 

More BEFORE and AFTERS....

Re: 1968 C10 Stepside Restoration Project
 

...and more...

Re: 1968 C10 Stepside Restoration Project
 

...and more...

Re: 1968 C10 Stepside Restoration Project
 

...and more...

Re: 1968 C10 Stepside Restoration Project
 

So, I am about to undertake what will likely be the most difficult repair of this build. The area up under the dash leaves little room for working. I will need to cut out the bad metal and replace it with good metal. Cutting, prepping, welding, and grinding will undoubtedly be a challenge. Here is what I am facing:

Re: 1968 C10 Stepside Restoration Project
 

As you can see the damage is relatively close to the dash mounting bolts. My primary concern is cutting out the bad stuff without mauling the good areas directly adjacent to it. While I will be using a grinder and sawz-all, my worry is cutting too deep or too far.

Repairing using an old inner fender seems to be the best bet, the inner fender has significant curves built into it that would make creating patch panels a little easier.

Re: 1968 C10 Stepside Restoration Project
 

You may find it much easier to pull the dash to repair those sections :chevy:

Re: 1968 C10 Stepside Restoration Project
 

I agree with Grumpy. Drilling out the pinch welds on the dash will save you a bunch and maybe finding a donor cab with that section the is good would be a good way to go. You have it down and are doing great work so either way you will get it done.

Re: 1968 C10 Stepside Restoration Project
 

I agree with you, but unfortunately there are no donor cabs in my area available that I can rob from. I'm going to see what I can do without cutting the dash out. I know that is not optimal, but I gotta do with what I have. My dash is in really good shape and I don't want to risk ruining it.

Re: 1968 C10 Stepside Restoration Project
 

Well I'll give you credit for doing all the work to save that cab , To bad your so far away ( about 350 miles ) I have a few parts cabs I'm using for my builds that I found when they were still cheap . a few bolts and some spot welds to pull the dash could save you a ton of time and a better result in the end ... :smoke:

Re: 1968 C10 Stepside Restoration Project
 

contact member heehawracing , he's down your way and may have what you need ? :chevy:

Re: 1968 C10 Stepside Restoration Project
 

Thanks Grumpy, I appreciate the lead. If I find I cannot get things how I want without pulling the dash, I will look at removing the dash and contacting Heehawracing.

BTW, I did do a test fit of the carpet yesterday...

Re: 1968 C10 Stepside Restoration Project
 

Just found this thread, awesome work man. following

Re: 1968 C10 Stepside Restoration Project
 

Thanks, I appreciate it. I am really grateful to all those on this forum who blazed a trail for me to follow on my build, as well as those like Paulk C10 and Gibson63 on YouTube. Those guys taught me a lot.

Hopefully I can get this cab finished up in the next month or two.

Re: 1968 C10 Stepside Restoration Project
 

So, I decided to drill out the spot welds and remove the dash so I can repair the area under rhe dash that is rotted out. Did not take long, I used a 1/8 drill bit to make a pilot hole (not really a hole, just drilled into the first layer of metal) then followed with the new bit I picked up thanks to a wise member of this forum who shared.

So once drilled out, I used my putty knife and separated the dash from the cab. Actually separated rather easy. I left one bolt in on each side so the dash so the dash wouldn't just fall.

Once repaired, I will apply the epoxy primer and Lizard Skin to ensure good coverage up under the dash.

Re: 1968 C10 Stepside Restoration Project
 

Here are photos of the process.

Re: 1968 C10 Stepside Restoration Project
 

The last photo above is showing that you also need to drill out the two spot welds outside to the left of the 'seam'...right of the seams on the driver's side.

Re: 1968 C10 Stepside Restoration Project
 

Finally, after removing the two bolts, the dash is free.

Here is a better look at some of the damage. I had already started cutting out what I could with the dash in.

Second photo I have cut out some more, wire brushed, and applied Rust Mort.

Re: 1968 C10 Stepside Restoration Project
 

So, in my attempt to recreate a period correct ranch truck similar to one my uncle had on his dairy farm, I decided to add a Unity GM spotlight. I picked up a really nice used spotlight off of eBay and was happy with how nice it was. All I need to do is replace the wire...easy-peasy. The bracket I ordered separately from Unity, it is the left handed Kdriver side) 202 bracket.

Re: 1968 C10 Stepside Restoration Project
 

Good job on the dash removal! I’m glad you decided to go that route, it will help you out , a lot!!!i have removed a couple, only hassle is, all that drilling...
Great rust repairs, you’ve accomplished!!! You’re a great inspiration for the rest of us!!!

Lol, looking for are to the “after” pictures of the inner dash repairs!!!
Carry on, man!!!