67 SWB Small Window Build

[67basketcase]

I guess bracing the cab and cutting it out doesn't bother me too much. It's supporting and balancing the cab while putting it back on that worries me.

[Low Elco]

The whole floor thing seems daunting, but I've yet to run into anyone who's regretted it. Look at it like this, a lot of cutting and welding, or a couple hours with a spotweld cutter? That cowl's gonna be a project!

[67basketcase]

Originally Posted by Low Elco

That cowl's gonna be a project!

Yeah, I'm not looking forward to that either. However I'm thinking I may do that first just to get it out of the way and give me something to be happy about.

[67basketcase]

After a lot of reading on here. I think it would be foolish to piece the floor together with patch panels. I'm going to go the whole floor route. That will have to wait a while tho, it just isn't in the budget right now. So I guess I'll busy myself with all of the other spots on the cab and just save that one for last.

[Vic1947]

Originally Posted by 67basketcase

After a lot of reading on here. I think it would be foolish to piece the floor together with patch panels. I'm going to go the whole floor route. That will have to wait a while tho, it just isn't in the budget right now. So I guess I'll busy myself with all of the other spots on the cab and just save that one for last.

I think you're making the right decision. On my '68 I pieced the floor together because it was relatively solid where it counted. In retrospect, I probably would have saved a lot of time by replacing the whole floor. The thing that got me was the poor fit of the patch panels. The inner rocker panels were too short so I had to scab material onto them to extend them out. And the floor panels are meant to lay over the existing rotted areas instead of replacing them. I had to trim them down and form a pinch weld lip with my brake where they meet the firewall. Also, if you need to replace the front or rear supports, it's virtually impossible to use a spot welder to install them. If you buy a full floor, all those problems disappear. Even at that, I'm sure there will be other issues that arise, but I doubt they will be worse. I'm about to find out on my '67. Based on my past experience, I bought a full floor for it, so I'll know soon enough.

I ended up patching my outer cowl rather than replacing it because I was concerned I wouldn't be able to get into the area along the lower edge of the windshield with my spot welder. I have several sets of tongs for it, but none would get into the very tight space along there. So I ended up cutting both ends off the cowl, doing the repairs to them and the inner structure around the vents and then welding it all back together. The inner structure isn't available from any source I was able to find, so you have to repair it as best you can. While the outer pieces were off, I rebuilt the water diverters and the pinch weld lip that mates to the firewall. After all that was back in place, I installed a new firewall. Looking at your photos I see the tip of the iceberg. Just keep in mind, it's all fixable. Patience ...and plenty of it will get you thru.

[67basketcase]

I couldn't resist getting something done before work this morning since I couldn't get away to play in the garage last night. Cut off the horse blanket seat cover to see what kind of horror was waiting under there. Surprising enough the seat was in pretty good shape. I've driven on worse seats in my DD before. Looks like it just needs a new cover and I might be able to salvage the foam. That wasn't enough, I still had ten minutes before I had to leave so I cut out the windshield. Two surprises in one day! None of the severe rust I was expecting, just a little surface in the corners. I was pretty nervous after the back window.

[67basketcase]

Finally "finished" my fuel system. I still need a new float, and four hose ends to connect the engine to the rest of the system, but I think the hard part is done. I really wanted to run a hard line between the filter and pump but it just wasn't going to happen with the angles and the short distance without remounting everything. It will work as is, just isn't as clean as I envisioned it. Oh well it won't be seen anyway.

[67basketcase]

Here's a couple pics. Pushed submit before they were done....

[67basketcase]

Went to work stripping the cab of everything that could come off Sunday. Had a little help too.

[67basketcase]

Of course through the process of dismantling everything I found a lot more rust I wasn't expecting inside the cowl. Non of these holes would bother me if I didn't have to cut away good metal to get to them. If nothing else it will keep me entertained until the budget catches up enough for the new floor pan. Took a few pictures of the worst of the passenger side rust and the pieces I cut this morning before work.