Big back window conversion tips
 

I started my big window conversion today and I came ascross a few short cuts. I drilled out the spot weld below the window/behind the tank, but instead of trying to drill out all of the welds around the lip of the window/underneath the seal. I used a grinder and cut off wheel and cut the outer metal of the donor cab. I cut it in a way that it was easy to fold it down at the window lip, opening up a "v" around these welds. I lightly hit them with the cut off wheel and just by working the two pieces open and closed/back and forth it popped the welds apart without drilling all of the welds. I continued to cut the outer part of the cab one section at a time and exposed the rest of the welds such as ascross the top headliner portion and continued the same process. It worked great and saved a lot of time drilling those hundreds of welds.

It ruined the rest of the outer metal, but all I wanted was the inner panel

Re: Big back window conversion tips
 

Another

Re: Big back window conversion tips
 

Another picture

Re: Big back window conversion tips
 

Panel removed, now I just need to clean it up and remove a coupłe pieces of the donor cab that are still attached

Re: Big back window conversion tips
 

Re: Big back window conversion tips
 

How are you going to put your BBW section in your truck? I have done Three and I use 3m panel glue its fast you don't have to put a hundred spot welds. I have used it for ten years and love it I have a truck in my shop right now if you want me to send you some pictures.

Re: Big back window conversion tips
 

I have a couple myself, I have a spot welder I use for most of it, simple and easy with no grinding to clean up. I use the 3m panel adhesive along the top where I can't use my spot welder.