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1/31/24 I started replacing the passengers side cab corner. After looking at the corner planning out the cut lines, I discovered that this corner was previously dented in about 3/4” and just filled with Bondo along with the flange on the “B” pillar. The good news is the replacement corner will completely remove the damaged area. The “B” pillar flange was formed completely with Bondo. It needed to be pushed back into place in order to meet the cab corner.

The inner cab corner had a few rusted thru holes close to the bottom flange that needed to be replaced. Welding went fairly well as I made sure I had good steel where I made the cuts. Once I finished welding in the patch, I coated the area with rust treatment.

The outer cab corner lower flange to inner cab corner lower flange had a gap of about 1/4 of an inch. I needed to make a wedge cut on the back side which enabled me to close that gap. On the door side the top flange was out about 1/16 of an inch and the bottom had about a 3/8” gap. I cut off the flange and ground the interfering piece until I got the gap closed. I then re-welded the flange back on.

Welding went really well until it didn’t. After completing the welding and grinding it flush, I placed a light inside behind the patch seam to show any areas I might have missed. I successfully sealed a few of the holes but on one hole I zapped it and blew a bigger hole. I backed it up with a piece of copper and welded the hole closed, looked again with the light and of course there were more pin holes. Zapped it again and blew bigger hole. At this point I decided I was just chasing my tail so I cut out a 2”x 3” section and replaced it with good metal. I still blew a few holes but was able to successfully finish welding in the patch.

This completes the passenger side cab corner and I am pleased with the results.

I also located a patch panel for my passengers side firewall. A fellow Stovebolter, “KCMongo” from Mongo’s Garage has the patch piece at a reasonable price and sending it to me. Once installed, that will complete the metalwork on the cab.