Well with the door off, and now we removed the left fender so to proceed. This side, while still fairly solid, still had some rust issues. As I had stated, both the cab corner and the lower hinge area had some issues. The parts order with the three parts making up the lower hinge door pillar assembly. I started on the cab corner. The door pillar also had rust, so I made a new panel to replace it. This part has some numerous curves and bends that make up the section inside the cab corner. The two parts that make up the cab corner did not fit very well. The outer part was pretty good, but where the inner panel meets the outer it was a long way from fitting. I was able to get it all together. As it turned out I should not have attached the door pillar to the cab corner. I later had to cut this attachment to get my line down the door opening to where I wanted it. Once this was off, I took the opportunity to clean and paint the floor brace. .
Now I went to work on the front door pillar by the lower hinge. These parts fit much better than the three parts on the right side. They were all welded in place. The step and rocker panel assembly was also removed. I made a new panel for the filler between the right lower door pillar and the step assembly. I made this out of 16 guage as again, this part carries a load of the floor and cab area. This brace was also cleaned and painted prior to boxing it in again.
Next was to install the step, and swap a stiffener brace to the outside edge of the running board. Once all that was OK, I dollied the floor area to mate properly with the flange on the step. Once it was all welded in, I was very happy with the end results. As I said earlier. I did rework the cab corner to get the door opening line to my satisfaction. I then put the final weld of the seam between the rocker panel portion of the step assembly and the cab corner.
Many of you know. The polar vortex decided to show up. It is making it difficult to work in the garage, so progress has slowed a bit. We are cleaning and painting door hinges, new pins and bushings, and other misc. Parts. Wr also went to work on the inner fenders sanding them and removing any surface rust. They are very close to being ready, but painting in this weather is not really in the cards. I also made a decision to return the inside door bottom in exchange for the smaller part and am going to replace the outer 3/4ts of the door skin instead. I had one bent with a 1/2" bend on 2 sides and will but weld it near the peak bend on doir..
