Couple of questions to ask and opinions wanted

[Greybeard]

In case the sound isn't the greatest I'm getting to the point that I might be considering this truck too much for me to fix.    However, the truck's paid for, it runs and drives OK, but it needs a ton of work on the rear suspension and the sheet metal as well as seals and other stuff.

The area that is shown here is the worst of the rust in the areas that are not normal rust areas. The other bad area is the spot near the heating cover at the point where the inner dash and the firewall connect (cowl area by the wiper mechanism on the passenger side) and there is some rust on the upper passenger door jam also, just not as bad as this. I believe I can simply fill those holes with weld. But opinions are wanted and appreciated. So here they are...

Click on picture



So, is it better to try and fill this with weld, cut it all out and try to fab some metal to go back in, or just fill it with bondo and forget about it? This is not the entire problem with this cab, first it's a two wheel drive cab, then it has a lot of bondo on the back for some reason (I chipped some of it off and I don't see any problems under it) but the left side of the cab up higher than a replacement corner panel will fix has been smashed and filled with bondo, it looks OK for now but the waistline is not done well and so it's crooked and bent. I'm seeing now why the previous owner wanted to get rid of it. But that was a decade ago so I can't complain too much.

I guess I better stock up on thin cutting discs, and flapper type sanding wheels because if nothing else I'll be using this truck for practicing my sheet metal welding skills on. Presently I have none so the only way I can go is better I guess.

[bake74]

     Is the rust completely through ?  What are you end goals with the truck ?  Are you going to pass it on or try to sell it someday ?
     If not all the way through, clean it up, weld it up and do the body work, it will outlast us.  If you are not ever planning on passing it on or selling it someday, then I guess the question is, how much work you want to put into it ?

[Greybeard]

It's going to be a learning experience at the least. So I would like to do it the hard way (the right way). Anyone can cover stuff with putty, I want to learn the welding aspect and use as little filler as is humanly possible. With that said, I'm not looking for perfection, it won't be passed on, and there are no plans otherwise. I'll likely keep it till the state takes it over from my estate at my death.

I just want to have it presentable as a truck, it will likely never get a paint job from anything other than a rattle can otherwise. I don't like rust, dents I don't mind so much if I made them myself; within reason of course. But as I said I really don't like putty as a coverup of major damage. The left rear side of the cab has that type of damage I think. I can see it's wrinkled up to just below the inner valance (inner wall) behind the seat. And the angle brace at the bottom near the rear deck (floor) is crushed. But there seems to be ample rust around the windshield mount too. I find new problems each time I look at it.  They dont seem to be insurmountable but more time consuming and money intensive (the likes of which I don't have yet). But I do have time and cutting wheels/sanding discs and a wire welder. So I was thinking there may be some stuff I can do until my new job starts in earnest when school is back in session (driving a school bus, THAT"S why I earned my bachelors degree! And now I'm going for my masters     I have NO idea why)   

[Greybeard]

Well, so much for keeping the truck presentable. 

I got a wild hair to see how the bondo was in the corner on the drivers side. it is worse than I expected>



So now the question becomes; are there replacement panels available for fixing this up to above the bodyline or will this be coming from a donor truck? I have looked for replacement panels but either I'm not using the correct keywords or they are not available past 20" tall. This damage goes to 28" minimum. Something must have really hit this truck hard. T-boned most likely.

I'll be looking for a replacement cab I think. That will most likely be the easiest course. Probably a complete truck, the problem is that shortbeds are few and far between around here in farm country.   

[VileZambonie]

I would find another cab, there's rust free ones still out there

[Greybeard]

I agree, however, I may still try my hand at the old art of metal bending with hammer, dolly and heat with a little cold water as a side dish. I'm patient. If I reduce the corner to dust, oh well, I'll have learned something...most likely that my hands can't hold onto a hammer anymore...

All I have to do here is get the area above the body line sort of flat and in position and it's not too far from that now although the body line is crumpled fairly good so I'll have to get that bodyline back to sort of the correct radius and then cut in a replacement panel below that. Sounds easy enough, but the proof is in the doing.

I'll still go and wander the Chevy graveyard near here to see if any are still in workable condition.