Fabricating New Cab Corner Help

More of an art than a science - discuss metalworking and welding here.



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PostPosted: Sun Mar 24, 2019 11:45 am
I am on here to get some advice from people who have been doing this for a long time. I know that the rust has gone through the outside metal and into the cabin, but what would be the best way to go about making a new corner piece? Thanks in advance. I'll attach pictures below.
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PostPosted: Tue Mar 26, 2019 1:35 am
I'm no expert but there are many ways to make a suitable cab corner including bending it over a pipe or other form to create the correct radius, using a shrinker/stretcher, notching and welding the corner, etc but IMHO the best way is to take your favorite credit card, rub it between your palms until it is good and warm, and then order replacement cab corners online. :P No idea what year and model you are working on there but when you can buy replacement cab corners online for $15-50 for many vehicles I think they are worth every penny. Just my .02, and good luck with the repair. :goodjob:



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PostPosted: Wed Mar 27, 2019 6:08 pm
Well i too am no EXPERT by any means nore am I a Profesional BODYMAN that works every day in a Paint and Body shop or Colision repair shop, HOWEVER I am a Profesional mechanic with a few years of Restoration experiance.
I can tell you from experiance that your Rust is far deeper than what you are seeing on the surface and IF you remove the head liner and look BETWEEN the interior panel and the exterior panel looking at that outside skin from inside the Truck that rust is more extensive on the inside than you think! so your gonna need to replace more metal than what you think!
Ya its rusting on the Outside AND the inside! (Check it out)

At any rate making Patches for that is gonna Suck!
IF you have to ask how to metal shape Patches for that trust me its beyound your current Tallents!
IF this is your first project lets get it done the easiest way possible! BUY a whole Roof from a Junk yard Truck.
There are just too many expensive tools to buy!
Just to get it done by buying the panels, Buying everything to do everything is cost prohibitive.

That is unless you already have every thing to do Paint and body work ?????
That would include a Big Aircompressor, air hose, plumbing, air drier, water trap, regulators, Mig welder/Tig welder/Gas welder, a Good set of Hammers and Dollys, Paint guns, Paint booth, Metal saw, Die grinders, Sanders, sand paper, supplies and on and on.

Then Metal shapping
Big Stump, Hammers, Mallets, English wheel, Bead roller, Welders, Saws, Shears, screws, Clamps, Clecoes, and the List goes on and on.

Seriously while that cab corner may look easy to do Your skill leve and what you want it to look like in the end come to mind.
I personally am looking for as Perfect as I can get to original for most of the work I am doing, You on the the other hand may only be consernd with just keeping the water out. So you need to be a little more creative in what your asking I think?

Are you looking for perfect? do you have any experiance at all? what Kind of equipment do you have? What kind of repair are you looking for? What kind of money are you looking to put into this project? What kind of money are you willing to invest in yourself? for the next project?

If are you only interested in stopping Rain and snow and you plan to scrap the Truck in a Year or two? Get yourself a Can of Fiberglass Filler, some Sand papper a 2 hp aircompressor a cheap $20 harborfreight gun some cheap Paint and go at. Lots of Videos on You tube explain every thing you need to know to do this sort of thing.

:knockout:
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Sun Jun 02, 2019 2:20 pm
Thank you for the advice, I've been saving some extra cash for a welder. I'm looking at a Hobart Handler 140 or the equivalent Lincoln counterpart. I plan on fixing this the right way, and have been informed by a lot of other people that filling the rust holes with fiberglass is only a temporary solution. And that is not what I'm looking for. I understand that the rust will most likely go a lot deeper than what it seems to be right now, and it will take a long time to completely fill in the rust holes.
I tried finding new cab corners, but have not had any luck with reproduction ones for sale online for my specific truck. I would also look for a roof from a local scrapyard, but there aren't any of those near me with the correct roof. Old Toyota pickups are very difficult to find in scrap yards in my area.
The end goal is just to have the rust removed, and make it look good. I don't care very much about it being factory specifications. I just want it to look good, and provide the function of stopping rain from coming into the cabin.
For tools I plan on buying very first will be: hammer and dolly set and a welder. I know there are thousands of tools you can get for auto body work, but like everyone else I'm doing it on somewhat of a budget. I can wait and save for tools I need, but if I don't have to have them then I will avoid purchasing them.
If you have any other questions, suggestions, or advice I would appreciate it. -Thanks



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PostPosted: Mon Jun 03, 2019 10:02 am
i have the hobart handler 140 and its a good machine for me. IF you pick one up, very first thing to do is look at the gauge and if it isnt a smith, contact hobart to get it replaced. they packed some rather junk china gauges with some machines. they arent accurate and leak.



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PostPosted: Fri Jun 07, 2019 3:16 pm
HattedToast wrote:Thank you for the advice, I've been saving some extra cash for a welder. I'm looking at a Hobart Handler 140 or the equivalent Lincoln counterpart. I plan on fixing this the right way, and have been informed by a lot of other people that filling the rust holes with fiberglass is only a temporary solution. And that is not what I'm looking for. I understand that the rust will most likely go a lot deeper than what it seems to be right now, and it will take a long time to completely fill in the rust holes.
I tried finding new cab corners, but have not had any luck with reproduction ones for sale online for my specific truck. I would also look for a roof from a local scrapyard, but there aren't any of those near me with the correct roof. Old Toyota pickups are very difficult to find in scrap yards in my area.
The end goal is just to have the rust removed, and make it look good. I don't care very much about it being factory specifications. I just want it to look good, and provide the function of stopping rain from coming into the cabin.
For tools I plan on buying very first will be: hammer and dolly set and a welder. I know there are thousands of tools you can get for auto body work, but like everyone else I'm doing it on somewhat of a budget. I can wait and save for tools I need, but if I don't have to have them then I will avoid purchasing them.
If you have any other questions, suggestions, or advice I would appreciate it. -Thanks


Your looking at a very big Job here, easiest and cheapest way is to find a New Roof from a wrecked truck. Find a reputable Body shop maybe to help you locate one many have contacts with wrecking yards all over the country. Even with shipping costs being hi you'll be money a head finding another whole roof.

That brings up welding
If you think you can just Mig spot weld metal on to the edges and fill those holes your wrong you'll just make a big mess and more holes.
A Mig wont do that plus you cant weld to rusty metal.
All the rust has to be removed before any welding can be done. In your trucks case not much of the original metal will be left before you get to good strong clean metal to weld too.

Sounds like your on a budget and don't have a lot of money or tools to do this job.
May even be your first car I have no idea?
BUT Seriously Who ever told you Fiber glass wont last is wrong.
Done properly it can last many many years. I have removed many a hack job I had no idea was there before stripping a car to bare metal many here have experienced this as well!

Is it the right way to do it? NO! absolutely NOT! will it last ? IF done properly It should and will last much longer than the metal will if moisture gets to it again.
Its what we call Hack work and highly frowned upon BUT if you have no money OR equipment and just wanna save whats their for another day down the road go for it.

Just buying a new used roof, new Welder, an air compressor, paint gun, water filters, Paint Base coat clear coat and primer, some sort of Filler, Body tools, and the list goes on with Sand paper not to mention thinners and grease removers you can easily spend thousands of dollars just to get started. This aint no cheap Hobby!
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.

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