Well, they were slow @ the shop. We planned to work on the truck on Fridays, but they're kind of diggin my project so the sheet-metal/body guy got started on the rear window conversion today.
In a very short time, he had the small window interior spot welds drilled out & removed the skin. It looks pretty decent under that inner panel (alot better than the donor big window cab was anyway).
We've had various discussions on how to positively attach the big window interior panel w/o burning the paint on the back of the cab. The solution was to cut the lowest portion of the small window panel where it makes the 90deg transition behind the gas tank. We'll bend this lip up slightly & use this portion of material as the 'flange' to attach the big window panel to near the bottom. The original spot welds (under the paint) remain untouched. We'll simply spot weld the panel where the cab wall recesses (every other recess, just like the factory did). By doing it this way, there is a .500" gap between the flange & the cab wall (because of the recesses in the rear cab wall). That gap will keep the heat away from the paint
. The door opening pinch flange will get spot welded; the upper seam will get panel adhesive.
The big window skin fits very tight.... it had to be pried out when verifying possibilities. A bunch of clamps were used to make sure alignment was spot on . . .... Everything looks good so far!