Crew Cab Build

[Bagd72Chevy]

There have been alot of crew cab posts lately, here's my rendition. Rather than just welding a truck back onto a burb I am taking the time to go with a more oem approach. Final assembly will be done with a Pro Spot Spot Welder. Due to the differences in the roof structure I think it is actually easier to stretch a truck cab and install b-pillars. But I already have a burb with a trashed back section so I will be doing extra work to put the correct roof structure in it.

This is the rather complicated roof structure of a suburban and why the roof is taller


This truck cab has some of the worst rust I have seen in the roof/gutters. Luckily I dont need that part. It basically peeled off


Windshield removed


The Dash was perfect save for a switch installed in left side so I removed it and saved as well.



With the spot weld cutter warmed up I started tackling the inner roof. My goal is to remove it at the factory joints and save it. Maybe stretch it to go back in or make a new one. Either way I need a starting point.

Top of windshield drilled and removed(it rusted through at sides)



Not sure if this upper A-pillar reinforcement is in the burb. Will find out soon


All drilled. Getting the back loose


With a little wrestling you can get it to this point


Parts Pile. Not too much rust in the inner, will repair


Scalped


Next up will be cutting the upper door jambs, floor and removing the rear section of the cab. Probably pull the gutters as well. You can see here the upper jamb spot welds to the a-pillar section and b-pillar section. just need to make it longer.


Also picked up another burb B-pillar from a member here. Going to disect this one and make patterns to make future B-Pillars. I have some ideas and plans on low-production stamping some of the pieces.



Got a little time to work on the cab again. Cut across the floor and cut the upper jamb pieces loose. I now have the back of the cab rough cut and ready to start fitting to the burb. Post #2 will be the disassembly of the burb clip.




Last image for Post #1. Moved some things around and put the two players in close proximity.