60-65 Cab Floor Rust Repair - My Journey

[BillyFrank]

Thanks for the kind replies everyone
I got a good amount done today.
I finished all of the spot welding, ground them down, and added some primer to see what it looks like all in one color (and to prevent surface rust).







I think it turned out pretty decent. The spot welds are still a visible in some areas, but I figure it will be covered eventually, and worst case I can use some filler to smooth it out.

I also plug welded the panel to the cab support



Once again, you can see that the holes don't line up. It's beginning to make me nervous.

That's it for today.. Wish me luck!

[BillyFrank]

Help!

After getting the inner rocker fully welded in, I test fitted the outer rocker panel to see exactly what it will be like. Everything looks perfect... from the top.

Underneath however, there is a problem. Back when I removed the original rocker, I remembered the 20+ spot welds I had to remove.



You can see how the welds connect the bottom lip of the rocker panel to the bottom of the inner rocker. When I test fitted the new rocker panel, the back does not come down far enough to be able to weld the pieces together. And what's worse is that it does this only on one end, but not the other, leading me to believe that It is tilted. I will post some images soon to show you, but if you have any ideas, I'm all ears.

[shortbed70]

Well you must have lmc panels? I had the same issue on the inner rocker on big red dog... The holes are off a lot of the times on panels just make sure before you make them permanent you try the fit other things around them ie doors fenders... I had to add a strip to my inner rocker to be able to spot weld the putter to it at the front on drivers side. Don't worry it's just Taiwan stampings.
Right about where the clamp is I was 3/4" short and tapered towards the back so has to cut a long wedge to make up.

[bj383ss]

As everyone else said those holes never line up. Redrill them using the old hole ad a guide

[Cape Codder]

If everything that shows lines up nice the stuff behind is easier to adapt. I repeat myself and others ,you need to test fit everything as many times as needed to get things right. I really like to screw the rockers and floor pieces together so the door can be fitted and tested for correct gaps. After welding remove the screws and weld the holes. When you have the door aligned you can spray a little paint over the bolts that hold it on so when taking it on and off you have a reference to quickly align. When everything is fitted welded and done some drill a small 1/8" hole through the hinge and door so when you take apart for paint you can realign with a small nail.

[shortbed70]

Good tip on the 1/8" hole! I seen that on a show and have adapted it into my builds and makes final panel alignment a breeze...

[1964GMC]

Good looking project, and GREAT looking work! About to start my own cab repairs. I'll follow you on your journey.

[RANDY COX]

Lookin good my friend, like you said that final trimming before welding takes patience..

[kvn1011]

some good info here!!
Google search brought me here!!