I have never repaired a cab corner before and since the cab needs both sides done I decided to do the passenger side first as it had less rot and didn’t need any extra bodywork. I have watched quite a few videos on YT and put together a plan that would work best for my ability and what tools I have available. I was so focused on the task I forgot to take a lot of pictures. I had the cab outer corners but didn’t buy the inners. Hindsight it would have been quicker and easier with them but after measuring, cutting, hammering and many, many test fits in between got a good fit and burned it in.
The outer corner was more challenging for sure as it round and not easy to get a clamp or vice grip on to hold in place. With a little patience(not my best attribute) I tacked it in place. One tip I will suggest is if you are getting frustrated and trying to hurry it will make it so much harder. I had to stop after getting it tacked in and come back fresh the next day as I was burning in some holes way to hot. I reset the welder and then took my time and it worked out ok for my first time doing it.
I can’t physically fit my hard in the side access hole and hold a dolly (tried for longer than I care to admit) so I couldn’t planish the weld at all. But with a straight line and keeping the heat as low as I could and still have good penetration on the weld it turned out acceptable for the route I’m going with on the truck. Since I cut on the panel and left the factory seam where the door closes to the cab it stayed in line.
I then started the drivers side by cutting to good metal but have a pretty big crease so I need to have the door on and adjusted before I work on the crease and start any welding (things you learn on YT lol). I started on the door and will focus on that next.
I would have liked to have done more but life can get in the way. The daughter got in a low speed accident with my grandson (they are both physically fine thank goodness) and the car it totaled. So I did dad and papa things to help them out as family will always come before working on my projects.
