ClusterTruck; because that’s what it is

[clay68c10]

The base of the pillar was fine on the other side, but all the rocker was totally rotten. This side was the opposite. Thankfully I had the whole kit, so that covers it all. I only used what I really needed since the shapes aren't really spot on.
Anyway, here it is.

[clay68c10]

At some point, this truck got a de-luxe house carpet install. No glue was used, but about 40 little screws. That was fun.

[clay68c10]

Here's something I've found helpful when cutting out metal in corners. A Dremel with a flex attachment can get in the corners way better than the 4" cut wheel. It takes a while, but you don't have all the extra cut damage from the big blade.

[clay68c10]

And finally, the rot is out. Time for some fresh metal fitting.
I like to creep up on fitment, so I cut the pieces slightly oversize and use a flap wheel to get it really close. I tack when the gaps are looking pretty good. It seems there are always some tight gap spots, and I open them up with the cut off wheel, either the 4" or the Dremel.
Now we'll see if my daughter wants to do some tacks this weekend. There's definitely no shortage of opportunities.

[Richard2112]

Great progress, looking good.

[SCOTI]

Mad props for keeping the young-guns inluded. I sure wish I did more w/my step daughter.

[MDPotter]

Rust repair on the cab is a time-consuming process, I didn't particularly enjoy it. But it's satisfying when you're done to know that your cab is rust free and solid.

And great that your daughter wants to get involved. How many girls her age learn to weld? Or even boys her age?

[Chevys4life]

I'm in Scrbd!!!!

[clay68c10]

Thanks all, I keep plugging away at it when time allows.
The kids think it's interesting but in the 11 & 7 year old way. Once it looks more like a truck and/or their driving years are on the horizon it will probably be a different story.
I try to expose them to non-screen activities as much as possible. You can "build" all sorts of cool things in Minecraft, but it's not real. That's a distinction that I think a lot of younger kids don't quite get, mine included sometimes.

[clay68c10]

Here's some of the last couple weeks progress.
In the above floor pics, you can see a thin triangle gap. Yes that is a total screw up on my part. I eyeballed that portion of the floor when I cut it, instead of measuring it. DOH
So I got to reinstall the portion I cut out. I generally keep my cut out pieces just for reference. This time it came in handy.

[clay68c10]

The kids were around and came to check it out. My son preferred to play with some cool sticks he found that look like guns (I remember those days). My daughter decided she wanted to do some tacks for about 20 minutes. That was enough for her at that point. I get it, a zillion tack welds do get old.

[clay68c10]

She did a pretty good job and I finished up the rest.
Next up was the last floor portion. Nice to see it coming together finally.
I started with some scrap and used a hammer and sandbag to get the shape close enough to work. Get the gaps close and then tack tack tack.

[clay68c10]

As a helpful side note, during the fitting and welding the gaps don't always stay consistent. I keep that dremel tool handy and use the cut-off wheel on it to get the gaps opened back up. I prefer to creep up on the dimension of my patch so it doesn't turn out too small. I can always open up the welding gap if I need to. Closing up a too-large gap isn't much fun.

[cornerstone]

Originally Posted by clay68c10

Yes that is a total screw up on my part. I eyeballed that portion of the floor when I cut it, instead of measuring it. DOH

I did the same exact thing. Gave myself a stiff slap to the forehead upon realization.

[clay68c10]

^^I hate it when I do that. I created at least an hour more work for myself.

Here's an example of my fitment technique with the floor support. I kept the old one I cut out and used it for a template. I cut the new one a little big and flap-wheeled it to the right size. As it got closer to the right size, each time I fitted it I bolted it in. It shifts around a fair bit when you tighten up the fasteners and that can give you the too-big gap problem. This is what I wanted to avoid.

[clay68c10]

And here it is done. I drilled the little hole in it for my wax application afterwards.
Speaking of drilling, you have to drill the bolt holes. I'm ok with that since it's a re-pop and I doubt they would be in the right place.

[clay68c10]

At this point, all that's left underneath is the fender tab, rear floor brace, and some misc. tacs in the couple of thin spots here and there along the long floor seam. There is a light at the end of the tunnel.
I got this far last night and called it beer:30. The rear brace was a little harder to fit but the gaps are decent. Nothing I can't work with.

[mongocanfly]

I don't go thru the 67-72 section much because theres so much going on here that I cant keep up with it all...but your doing some good work,,,and kudos for having the kids involved...I vividly remember as a kid helping my Dad work on his trucks, tractors and cars

[clay68c10]

Thanks Mongo, it's a long process but fun and challenging.

I got a little more done here and there. The floor is pretty much done!

[clay68c10]

It's sitting back right side up on the casters!

Of course, the motivational shot of the panels just set on it.

And a back side shot of the corner. I chose to cut it here so I could get to the back side of the weld and make sure it doesn't have any pinholes. It wasn't real crusty up this high, but I'd rather be able to get to both sides of the weld seam.

[clay68c10]

The corner is cut and fitted. I got some welding done on it. I’ll need to open up my gap for the rounded edge area. Maybe this week. Or after the 4th. We’re going to Wyoming for the holiday, so camping, hiking, and shooting will be the plan!!

[doowoppwer]

subbed

[clay68c10]

Back from Wyo, had a great long weekend.
Had some more progress this past couple of days. The cab corner is pretty much in and done.
The usual zillion tac welds.

[clay68c10]

At this point, I like to start grinding the welds down and look for pin holes.
I'm a fair welder, but very realistic about how this goes. The gap isn't always perfect, the metal isn't always spotless, my welder is a decent one but not some hi-zoot machine. And my technique/work angle/eyesight isn't perfect every single tac either.
That said, get the brightest light you have and start shining it thru from the rear. I usually find a couple of pin-points to fix.
When I do this, I make sure to trim the "ball" off the end of the welding wire EVERY time I tac. This is the time to get those pin holes filled, and that pointy wire will get the heat in there better.
Definitely use a sharpie to mark them, you can't see em without the light, so I can't find them again unless I mark them. Then grind and repeat. Maybe you missed one and now is the time to get it done.

[clay68c10]

The bottom curve of the corner was a little off on this side, same as the other. I got it shaped up and put in a tiny tac underneath just so it wouldn't move around. Prior to this little tac, it did shift a little. I wanted it to stay put while I was putting heat into my upper seam. I'll put a couple more on the bottom when I tip the cab up for (hopefully) the last time and do my undercoat/wax.