Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Well we got the suburban home and inside to dry off, I don't think I have ever seen a vehicle with this little amount of rust but I guess that's what you get when you live in the rustbelt. all of the doors open/close and all the windows go up and down but I need to put the wing vents in the front. I now see the difference in the roofline on the trucks and the suburbans so I will have to figure out what to do there

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

So we finally began working on the 4th door pillar, after getting a piece of 18 gauge steel bent to almost perfectly the correct main shape we cut out the 4th door panel in one piece so we can use it. next step is getting the pillar welded in and to begin adding all of the little "features" into it to match the passenger side.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Before we start cutting we are getting all the door gaps correct so when we make the 4th door and cut the back off the doors need to be correct. the front drivers suburban door had some rust and the window frame was jacked like someone put a 2x4 in the door and slammed it so we are going to use a clean truck door and put the suburban window frame in it.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

We got the 4th door pillar in place with screws and are working on the latch for the front door

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

I like the plan you have.
It's looking good.
Each of us have our own idea of how it needs to be.


Are you using most of the original stuff on the front of the 4 th door pillar?
If you are I like your plan.

Great progress.








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Re: 1972 Chevy K20 Extended Cab Cummins Build
 

I am not quite sure what you mean, the plan so far is we have the pillar that we bent and put in place, now the goal is to try and replicate the hinge and latch mechanism from the third door pillar to make them the same.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Also the roof has been cut out so we can make the door jam for the fourth door and flatten the roof. the front window area is rusted so we need to cut it all out and weld the a pillars and roofline from the original blue truck in place.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

I was focusing to much on pic #5 in post #42.
Instead of pic 1 & 2 in post #44.

The main thing I noticed. I like how you are using the interior plate
in pic #1 in post #44.
I was going to make it. I may try to use it now.

Your templates are great.:metal:











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Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Yes I plan to use as much of the original "4th door" as possible to make the functional one, I do have an extra drivers door if I need to use it in the end

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

we cut out the rear of the door jamb from the passenger side of the suburban third door and drilled all of the spot welds out so we had all of the individual pieces. the plan is to use them to form the 4th door front jamb and the rear will be the truck cab, the part we cut out on the passenger side will be filled in also with the truck cab.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Getting it figured out.... that's half the fun!

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

today we got the door latch pocket tack welded on in the correct position and the weather stripping lip from the rear of the passenger side cut and re shaped to fit the front of the drivers side.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

got the upper door jamb spot welded in and working on the lower pillar, almost done.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

today I worked on the various puzzle pieces that will be welded to the 4th door pillar to match the passenger side, I hope to be tacking them in tomorrow

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Your making super fast progress on your post. Looking factory to me. I love seeing how different peoples approach to making this pillar are. Keep up the good work. Took me about two weeks to make my post... hours of welding ahead of ya..
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Re: 1972 Chevy K20 Extended Cab Cummins Build
 

yeah its getting really close to being able to be welded, the latch mechanism will fit and work in the current state but to make it the same as the other side I need to sink the pocket into the post another 1/8th.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Got the rear of the pillar tacked in place and the latch pocket moved back where it needs to be.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Got the bump out on the pillar tacked on today, feels good when stuff fits like its supposed too.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

today we got the pillar welded in and the temporary latch for the drivers door made and installed so it all works, tomorrow the plan is to get the suburban cut off and the back of the truck cab put on

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Sunday we got the suburban back off and the truck back sat on, the nest step is to mount the rear to the cab

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

got the cab sitting in a more correct position, had to cut out the window track as expected and lined the drip rails up with clamps

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Amazing work.

Jack

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

got the rear cab tacked to the suburban, we made an 8 inch long inner support manel to tie the two together and even with a few welds seems very strong, the mock window pillar is also welded in until we use a full other pillar to weld into the door like the original, the two line up real well. mucking up the cab corner to make sure everything fits an then lock down the drivers side so we can make that door. also I buffed out the original Ochre door that will contribute to the fourth door to look at it in person. I was set on blue but I have always liked the yellow and I think that is the direction I will go, with the white top and no trim.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Looking good.
Great progress.
I like that Ochre color also.









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Re: 1972 Chevy K20 Extended Cab Cummins Build
 

That color will look good. Nice progress! What’s the white stuff on the green grass?

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Yeah it was 78 one day and snowing three inches the next, crazy weather

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Looking good!

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

got the drivers side cab corner on and looking good, the rocker is just screwed in place. the passengers side cab corner was welded on but the corner didn't fit right and tapered in on the bottom, after checking the contours of another cab we realized they both should be the same and the passenger side is not, most likely it was twisted while doing the drip rails. we just need to cut and form a bit until its close. also the drip rails line up perfectly on both sides.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

The contour as compared to the drivers "correct" side.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

work on the project is on hold right now as we bought a theft recovery 2019 Duramax and had to put it back together. I was looking through the "Trucks in the Wild" Thread and came across a picture of the White C20 I bought from 2018, sitting in the same exact spot as when I picked it up, thought it was interesting

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

I am hoping to start back up on this build here soon, the plan has changed, I put the 12 valve 5 speed into a ext cab short bed dodge, I sold that truck and made some money, I have now switched to a duramax chassis for my swap. I got a donor truck a month back, 2005 lly crew cab long bed.

Re: 1972 Chevy K20 Extended Cab Cummins Build
 

Too bad you're in Indiana, I need that 06 HD hood! Great progress on the truck.