Found rust in all of the usual places, and in a few we didn't expect

[rainman15]

The body work is coming along nicely on my 84.  We did run into a few unexpected issues around the windshield but other than that it has been pretty much what we expected.  The truck should be done by thanksgiving I hope. Here are some updated pictures. Lessons learned so far, I already regret not buying a full bed skin for the drivers side. Having 3 patches on that side, front rear and above the tire is too much work that will just come back soon anyway. The new aftermarket drivers door was not exactly what you'd call a direct fit either. It took a full date to massage it into alignment.  Aside from that and the rust under the cowl panel we are in good shape.  

[fitz]

The new aftermarket drivers door was not exactly what you'd call a direct fit either.

What brand of aftermarket door dod you use?

[rainman15]

I'm not sure who the company was that built it but it came from competitor trucks.  They probably bought it from somebody in china...

[rainman15]

It looks like the drivers side of the bed is going to be too bad to repair.  I already have the patch panels for above the tire, behind and in front of the tire, which would have been enough work to do right.  After pulling the bed side rails, tool box and left rear brake light we've found a bunch more rot than we expected and it is just not reasonable to try to cut and replace that much metal in places that will be that visible.  

The rest of the bed is in really good shape though, inside is flawless, and the passenger side is good too, so I'm thinking buying a bed skin for the drivers side is the most reasonable option.  Problem is I don't see anyone that lists a part number for a shortbed drivers bedskin for an 84 with the square fuel door.  I only see a panel for 73-78 and another for 79-80.  Could I get by with one of those?  What is the difference between the side of a 79-80 bed and my 84 bed?  Any difference at all?

[three8six]

The gas lid holes are different is all I know. Also its not really a skin, its really the entire side of the bed. Not sure but thats prolly why your not finding it.

[78 Chevyrado]

Before you paint it, put the new weatherstripping around the door opening on and check the doors fit then.  sometimes the top of the door needs to be bent inwards a bit and its a lot less scary to do if there's not new paint on it.

[VileZambonie]

Keystone lists it for $244.55 w/o the fuel door. 73-87 will all interchange. The only major difference is the round, square or no fuel opening. You can fabricate your old one into the new panel if it's still in tact.

[Cody1018]

A good way to fix the rust around where the window rubber sits is to take some sheet metal and form it to the shape, put some tar on the side that you wont see, drill some holes and pop rivet it to the truck. My truck had the same exact problem with rust there.

[75ChevyGuy]

Holy moly! Thats alot of rust and rot. I take it it's seen a few to many winters?

[rainman15]

It never saw any winters, it has been a southern truck all its life. It was kept on an island on the NC coast which is where the salt spray from the ocean came into play causing all that rot.  It is all fixed now except the drivers bed side.  I finally found the bed skin I needed with the square gas hole at a place in Kansas City.  It is on its way in shipping right now and we hope to have it on by the end of next week so we can get it into paint by the weekend.

All the rest of the truck is done except the left side of the bed.  We did take the advice of checking for door fitment issues with the rubbers installed prior to paint, and it seems to be a good tight fit up top and down on the bottom, which is pretty remarkable considering how much work it was to get that aftermarket replacement door straightened out and to make the seams match.  It was twisted pretty bad  in shipping.

We already sprayed the inside of the cab and have most of the interior back in, all glass is back in except the rear glass which still needs a gasket, and everything is prepped and ready for paint once we get the bed ready.  I'm just so excited to finally get this done.  It has been a dream of mine for many years to do this truck right and it is finally coming true! 

[topp]

A good way to fix the rust around where the window rubber sits is to take some sheet metal and form it to the shape, put some tar on the side that you wont see, drill some holes and pop rivet it to the truck. My truck had the same exact problem with rust there.

And when the rot you covered spreads that piece you put on there will fall off..
Thats not a fix, but a temporary patch...

[Cody1018]

And when the rot you covered spreads that piece you put on there will fall off..
Thats not a fix, but a temporary patch...

Its something you do when you dont have the money to fix it right...

[rainman15]

Well this project is one I'm investing quite a bit of money in and trying to make sure all the repairs are done to the highest standards.  Any part that had rust that could be replaced with a new part got replaced.  Any placed that had rust and the entire panel couldn't be completely replaced, we cut the rust completely out and patched with new sheet metal.  Unfortunately that means it has taken going on 60 days longer than I expected, and I'm about $3500 over my projected budget, not counting labor.  

This week I found that the rear window gasket that came with my weatherstrip kit doesn't fit the factory sliding rear window, and in fact the gasket I need has been discontinued so there is no way of keeping the factory chrome trim in the middle of that rubber strip around the glass.  I had to buy a complete new sliding glass.  Not a big deal I guess but I really wanted to keep it as original as possible and losing that trim piece just pisses me off. 

The very next day we finally got the drivers side bed skin fully properly mounted (we just had it tacked in place while we touched up a ding from shipping before) and once we tried to shut the tailgate it scraped a little. No big deal right? Well once I stood back by the brake light and looked across the top of the tailgate I noticed why.  The dang tailgate is bowed in the middle, like someone sat a car engine on it right in the center with the tailgate down. I can't believe I never noticed it before, so I had to order a new tailgate too.  Yet another set back, more money I hadn't planned to spend, and more time wasted waiting for parts.  It just never seems to stop.

[rainman15]

Finally got some color on.  The cab and bed are finally blue again.  All we have to do now is move some stuff around and retape for the 2nd color.  It is a blue / silver 2 tone paint scheme.  Hopefully be ready to shoot the silver and start reassembly by mid week. 

[rainman15]

My buddy just sent me these pictures. He finally got the 2 tone done.  Reassembly starts next week and I will hopefully be riding again the week after that.