Budget Shortbed: welding, grinding, rust oh my

[Chevys4life]

Originally Posted by 72bowtiestepper

Very nice work from someone that did most of the panel replacements that you did ( but not as neatly !) It takes a ton of time to get these old trucks back on the road after being rusted top to bottom, but looking at & driving them when finished makes all the work worthwhile. I used a Miller 115 volt MIG to do mine with .025 wire & argon CO2 mix gas. Doing the work yourself is VERY rewarding when the job comes out good !

That's the best part about what you said. Being able to know that you did it yourself...........that's priceless.

[HO455]

Originally Posted by Onry69CST

HO455 - I've seen the Silicone Bronze too and it is really awesome. I'd like to give it a try one of these days. The only thing about it is it's actually brazing, not welding. It's still plenty strong for non structural body panels though.

Not to hijack your great thread too much. The demonstration was put on by a welding vendor (Obviously to sell equipment) but it was important for my buddy in that some of the OEs now days are using Silcone Bronze for structural component assembly. The new light weight panels being used to construct the body shell are no longer being made of low carbon steel and welding them compromises the tensile strength of the panel. It seems we have come full circle from the early 1900 and are brazing our cars together again.
Hijack completed. Please continue with your great work.
HO455

[Onry69CST]

Not a hijack at all! That's a great point, lighter guage structures mean better gas mileage, less expense in raw components, and all sorts of other things that tickle the corporate pocketbook. Alot of OE robots are set up to production "weld" the light guage components because it really is a great solution for that. I have to assume that they do thier fatigue stress and element analysis on the design with consideration to the brazed joints.

[Onry69CST]

Originally Posted by clay68c10

Nice work and documentation.
Definitely put a door on before you get too far fitting the outer rocker. You may find that the outer face of the rocker has a bow to it. Higher in the center and lower at the front and rear. That’s what I found with mine. You can see it in my build thread, along with the same fitment fits you went thru.

Thank you, I looked at your thread and your work is very nice! I always enjoy seeing and learning different perspectives and strategies to performing the same work.

[Onry69CST]

Originally Posted by 72bowtiestepper

Very nice work from someone that did most of the panel replacements that you did ( but not as neatly !) It takes a ton of time to get these old trucks back on the road after being rusted top to bottom, but looking at & driving them when finished makes all the work worthwhile. I used a Miller 115 volt MIG to do mine with .025 wire & argon CO2 mix gas. Doing the work yourself is VERY rewarding when the job comes out good !

I agree 100%, it's all worth it in the end, and you get to save a peice of history you can really enjoy.

[Onry69CST]

Last night I rough fit the rocker and hung the door. There was a little bit of massaging on the front peice to get it to sit in the right spot. The backside came up about a quarter inch short of the top of the B pillar, but it can be clamped into place. I also ended up taking a section of the cab corner out to contour it to the rocker, and achieve a consistent gap between the two. The only ill fitting area left is the bottom spotweld seam on the b pillar end. Once I start welding it in, it should be easy to knock all the corners in tight.

[Onry69CST]

I mounted the door, and after an hour or two, I think I've ended up with the best fit I'm going to get by myself.

I don't like it as it sits. If I can get another person to help me shift it up, and clockwise just a bit then it may be decent. I don't think I'll need to do any major rocker adjustments either way, but that could change.

[Onry69CST]

I finally finished the driver side metalwork completely. I was able to get the door positioned better too. I also had to make two last panels just inside the inner rocker. Time to do it all over again on the next side

[KevinK7]

excellent welding/work. Thanks for taking the time to photo and post

[72 tigger]

Good progress

[HO455]

Good work!
If I may on your door alignment if you have a problem getting it all to come in even all around you might have the same problem as the drivers door on my Burban. The window frame was not welded in the correct position and prevented me from getting a good alignment. Another plus of owning a truck built on Friday. If the front or back is off by 1/8" it will jack the opposite end out of spec. It required cutting the spot welds on the rear and repositioning the frame correctly back to the door.

[Big H]

I know you still have plenty of work left to do, but the work you have done to date is pretty awesome. Pat yourself on the back.

[Onry69CST]

I've been busy working and not posting so here's an overdue update.

I completed the metalwork on both sides and sealed and painted it all. The cowl vent area on the passenger side was thin enough to poke a finger through, so I cut section out and found a real mess. I had to make panels for the vent tunnel, and floor of the cowl side. I'm guessing most trucks have a similar dirty secret.

I checked the other side, and it was similar but not as bad. I decided to vacuum it out as best as possible and por15 it from inside and out which was real tough. I also cleaned and applied por15 to the cowl to firewall lap from inside the cowl, and seam sealed it. I continued seam sealing everything that looked suspect.

[Onry69CST]

I guess I didn't take any other floor pics. Here's the cowl.

[Onry69CST]

More cowl stuff. I took a short break to restore an old finger break I've had that needed some work before I could form my new panel.

[Onry69CST]

Trying to match the oxidized hugger orange, I'm trying Chrysler hemi orange. We'll see when I do the doors, I know it won't be perfect but I'm not extremely concerned.

I also picked up a Dodge buddy bucket which I'm really excited about. I'll make some mounts for it shortly. I figure I might as well put a halfway decent interrior in it now, and I have some extras from my 69 CST that will fill in the gaps.

[HO455]

Once again great work!

[Getter-Done]

Nice pattern making for your Sheetmetal.
Great job.
What kind of finger brake are you using?











.

[Onry69CST]

Originally Posted by HO455

Once again great work!

Thanks!

Originally Posted by Getter-Done

Nice pattern making for your Sheetmetal.
Great job.
What kind of finger brake are you using?

.

Thank you! I folded the paper over the panel I cut out and rubbed the bend lines and edges with my dirty hands to transfer the lines to the paper. It's an older 24" Di-Acro, and is 300 some pounds if I remember correctly. I got it broken, I think it took a fall, but after I fixed the handles and reassembled it you'd never notice.

[KevinK7]

amazing work for sure, looking great !
...I have the same Diacro brake, that thing is like a tank

[clay68c10]

Nice job man!
That’s a cool little brake, perfect for this kind of work.

[Onry69CST]

Thanks guys. It is a nice little tool to have around. I welded up the holes in the doors and am doing some bodywork on them in preparing to match the condition of the rest of the truck, should be interresting. A side note, if you have big holes to fill, I use carriage bolts, or even roofing nail heads as a patch. Just watch welding plated material without decent ventilation, it can make some bad fumes. I've been meaning to pick up some acid to remove plating for odd projects like this.

[35boulder]

I agree with everything said so far. Nice work for sure. Really appreciate your time in documenting all this for all to see. Well done.

[Davidf]

looking good. I just finished replacing inner and outer rockers, lower hinge post, kick panel bottom, floor at kick panel, and factory screw ups on my '71 long bed. About ready to get the interior color back to Ocre from awful generic yellow.

Pulled the windshield over the weekend and very little rust at the seam/channel.

Oh, passenger door need major rust repair, drivers door in good shape. Patching/welding is done for the most part on my refurbishment. I want to use my '71 as a truck so not going the full restoration path.

Good luck, keep up the good work.

[Onry69CST]

Thanks, good luck on yours too, sounds like it will be nice.

I painted the doors to try to match the rest of the truck. With a little airbrushing I think it will work. The cracking on the driver door was unintended but I guess it's ok.