Hey Guys,
I want to attempt to replace the passenger side cab corner and rocker panel on my truck (1992 S10) which have rusted out. I am confused about what type of joint to use on the cab corner a lap joint or butt weld. What do you recommend?

Ive done both. Its a lot easier to cut it with an inch or so of overlap and cut the corners and tap it in a hair to make the existing metal lay in lower and do a lap weld. You can also cut it to size and do a butt weld, but working in a production it just takes too much time. Either one works as long as the remaining metal is free of rust and prepped properly before welding.

Good luck!

Thanks for the reply/info. I can get some clamps from Northern Tool for butt welding sheet metal and will probably use those when the time comes. My big concern is making sure there are as few seams as possible for moisture and debris to get trapped in so it won't rust again.

I prefer to butt weld wherever possible.
Having an overlap of metal creates a pocket that invites rust IMHO. The only option might be when using panel adhesive in non-structural locations. I haven't used a lot of adhesive but when I did it worked fine and filled the overlaps completely.

I like butt welding also. Dont forget to treat the inside with something when your done. 3M makes some good products for this...

But weld and weld through primer or just any primer is better than nothing on the inside.

bran1har wrote:But weld and weld through primer or just any primer is better than nothing on the inside.

I can agree on weld thru primmer BUT ANY primmer? NO
Nothing on the back side is better than having contamination in your weld.

Ideally both sides of any pieces of metal should be clean clean clean metal before any welding.
(weld threw primers can be used but arnt necessary)

Loose the panel clamps you want the metal butted up to each other NO Gap.