Big back window conversion part 1

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As you can see the damage to my cab corners. I wasnt able to drill out the final welds as my corners rusted out so the pieces just came apart. next step is to drill out welds holding inner cab wall.

1. take your time drilling inner roof welds taking caution not to drill through the inner roof welds and remember the inner pillar welds are more in number than you might think, some are in a stair step pattern.

2. I didnt drill all spot welds between inner and outer window cuz i was lazy. instead i drilled a few, enough to create gaps between the two surfaces and then i simply popped them with screwdriver since i have no intentions of using them again except for scrap metal patches in future.

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you can see how thin the roof metal is but take your time.

1. There is also a small tab on the corner of each side post holding the lower corners of the inner window onto the cab that must be removed also.

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Ladies and gentlemen, we now have room to start the conversion.

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Now its time to look at the new inner and outer portions of the BBW panels.

1. I got these parts from a warehouse in AZ called Classicdiscounttruckparts.com

2. The outter skin $401.95, the inner wall plus two internal bracing posts $200.95. Shipping $165 truck freight to my door.

3. The stampings on these parts are of very good quality.

4. The inner wall corners come with the door latch striker mounting brackets already attached. These will need to be cut out as i am not cutting out the original striker plates. Leave the outer curved wings attached (do not cut)

5. I have attached a photo of what the bracing should look like from rear of cab with only inner wall installed. Take note of the tack welds holding the bracing on upper corners of inner back window panel and the plate portion covering the door latch striker plates. you may have to save picture and then enlarge to see the tack welds.

6. This is as far as i have gotten. I need to find out if i have to trim the front facing sheet metal that goes directly behind outter pillar or if its supposed to be there.

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the last picture from post above show the curved braces and the panel that covers rear of striker panel. I have not confirmed yet but looking at earlier threads from other members, it appears that you have to tack the lower inner rear window assembly to the rear outer skin to strengthen the whole structure. Members who have did this mod please chime in because it will be thanksgiving weekend before i finish this up. Thanks and i hope this helps you guys. I am not an expert by any means, i just hate having to pay people for stuff I can do. I havent event gotten to the front panel replacements to include steps. just gotta have that big window.