** YOUNG FRANKENSTEIN ** The truck Chevrolet should have built.

[drewskiren]

To make the proper dimensions for a short bed you need to cut 8 inches out of the back and 12 inches out of the front. The tape I used was 7 and 7/8ths wide apart, allowing for 1/16th blade width on the cuts for 8 inches. 1/8th less on the front cut also. My favorite tool for long straight cuts is a Sawzall with a very long metal cutting blade. Lay it in the metal at a really low angle and it doesn't push/pull the metal back and forth. A 4 inch grinder with a 1/16th thick cut off wheel works almost as well if that is what you want to use.

[drewskiren]

Uh Oh, isn't that a little too short?

[VA72C10]

definitely a clean bed....and the right way to do these projects (find great sheetmetal to start with). Purists will be upset you cut a clean bed but that's the way to assure you have the best product.

[drewskiren]

Friday morning arrives and I thought I should take a pic of the tools of the trade.
As I start to clamp it back together I encounter what I expected on the body line at the top no longer lining up. Rokcrln shows what to do in his post, (highly recommended), simply move the metal around to line up and tack a spot. He doesn't cover it, but you should definitely work the 2 parts together from top to bottom. If you were to tack it in the middle or down at the bottom you can end up with a pooch in the metal somewhere in the middle of the panel. Take your time and don't heat the metal too much with several close welds in quick succession.

[Dieselwrencher]

Very nice! That was a super nice bed! That will be nice to know in 10yrs after the truck is done what you actually started with. Is that just aluminum speed tape you used?

[drewskiren]

The stiffest part of the bed is the bed corners, so I started there knowing that area is a constant.
Next I lined up and tacked the top bed rail, then the inner bedsides. Last will be the outer skin that I will need to wingwarp around to make it look right. Remember to go top to bottom

[drewskiren]

Originally Posted by VA72C10

definitely a clean bed....and the right way to do these projects (find great sheetmetal to start with). Purists will be upset you cut a clean bed but that's the way to assure you have the best product.

Originally Posted by Dieselwrencher

Very nice! That was a super nice bed! That will be nice to know in 10yrs after the truck is done what you actually started with. Is that just aluminum speed tape you used?

I can't tell you how fired up I was when I cut it open!

Not sure what Speed tape is, I just pick this stuff up on my jobsites, it is a metallic tape my HVAC contractors use to seal the ductwork in my houses . I love this tape, super sticky, forms well, and the price is icing on the cake. I just wish they would leave more.

[drewskiren]

Night time on Friday. Whew!

One thing I forgot to mention was that while I had the bedsides wide open, I went ahead and undercoated the stink out of them up inside just for good measure. When else would I have such a golden opportunity??? That's what the black spray is on the edges.

Mostly tacked back together now.

I used the orange straps to pull the parts together to get the tight spacing for a weld. You need about 1/16th space when butt welding for good penetration.---- Heh Heh, he said butt.

[drewskiren]

Here is a pic of what happens on the bottom edge at the rear as you work the body line out to match up. I will simply trim this as a long straight line later.
I figured out later that it is best to make most of your welds, but not solid. Wait until after you grind them down the first time to fill in completely with solid tacks. The problem is that when you have small mounds of tacks and you try to aim for that 1 last hole, you end up welding on top of a weld and that just makes more you have to grind off later.

[drewskiren]

AHHHH grinding. I promise its much more fun on the dance floor.

This is the pits, but must be done slowly and randomly to NOT heat up the metal. If you see blueing, stop! Move on to another area and try not to do it again.

[classicchev]

HAHA, your shop looks like mine. Woodworking stuff and materials scattered behind poly. Im a contractor also, my shop doubles as a cabinetshop, spray booth and a place to work on my crap.

Looking good, the more I look at this , the more I want a 67 72 crew, instead of a 79....

Darren

[drewskiren]

I ground some on Saturday (5 hours) and about the same on Sunday after church. I am nowhere near finished. I am grinding and then welding up holes as I find them, then grinding some more. Now I understand to try for better, smoother welds. This is my first real welding job, so cut me some slack.

[drewskiren]

Originally Posted by classicchev

HAHA, your shop looks like mine. Woodworking stuff and materials scattered behind poly. Im a contractor also, my shop doubles as a cabinetshop, spray booth and a place to work on my crap.

Looking good, the more I look at this , the more I want a 67 72 crew, instead of a 79....

Darren

You know you want it baby!

[Dieselwrencher]

Nice work! Keep at it. When I used to work in a body shop, my old boss always had us grind down the welds with a cut off wheel because it heats up the panel less and you have more control on top of the welds. It did seem to work better after I tried it.

[drewskiren]

I couldn't stand it, I had to see what it looks like.-- An Arizona tailgate on a California bed!

[brn agn]

Here is an idea for you (if you have not tried it yet). I have found that grinding the welds down with a thin cutting disc on the angle grinder will prevent the metal from getting overheated. After I get the welds close to level, I finish them off with a flap disc. It may be worth a try to see if you like it better. Either way, you end up digging black stuff out of your nose and ears for the next few days!

[Strut]

These would have made that alot easier....

Amazon.com: Northern Industrial Butt Weld Panel...
I use them alot myself... Work really well.

[drewskiren]

Originally Posted by Dieselwrencher

Nice work! Keep at it. When I used to work in a body shop, my old boss always had us grind down the welds with a cut off wheel because it heats up the panel less and you have more control on top of the welds. It did seem to work better after I tried it.

Bound to make it slower, but safer. I'll try it out, thanks.

[drewskiren]

Originally Posted by Strut

These would have made that alot easier....

Amazon.com: Northern Industrial Butt Weld Panel Clamps - 4-Pc. Set: Home Improvement

I use them alot myself... Work really well.

I have these, but grew tired of fiddling with them. If you look closely you can see them in the bed. A real pain to put together. A flat magnet or a prying screwdriver were faster and easier.

[Strut]

Originally Posted by drewskiren

I have these, but grew tired of fiddling with them. If you look closely you can see them in the bed. A real pain to put together. A flat magnet or a prying screwdriver were faster and easier.

Yeah, I know what you mean... They're good for holding the metal though.

[Dieselwrencher]

Originally Posted by drewskiren

Bound to make it slower, but safer. I'll try it out, thanks.

At first I thought it would be slower too. Once I got the hang of it I could move the cut off tool up and down or side to side and take off the high spots and then level it out. It actually goes along pretty fast. Like already mentioned, those flap discs are pretty sweet for finishing it off. I grind everything with flap discs anymore it seems like.

[drewskiren]

Originally Posted by Dieselwrencher

At first I thought it would be slower too. Once I got the hang of it I could move the cut off tool up and down or side to side and take off the high spots and then level it out. It actually goes along pretty fast. Like already mentioned, those flap discs are pretty sweet for finishing it off. I grind everything with flap discs anymore it seems like.

I have flap discs in the picture, just haven't ground down far enough to use them yet, still finding holes to weld up. I need to finish up quick, I'm ready to move on to the next phase.

[67chevy1series]

that looks sweet so are you putting top and bottom trim on

[drewskiren]

Originally Posted by 67chevy1series

that looks sweet so are you putting top and bottom trim on

Yes I am. Should look something like this.

[Dieselwrencher]

One question I have just because I'm curious, that's all. What is your plan to get the body line straight on the rear section where it doesn't line up? I'm guessing cut and weld? Post #183, last 2 pics.