Re: Crew Cab build preview...
 

There are detailed pics on some of the build threads on how to make the door, I used that information and it made it easier, its a lot of cutting welding and fitting.

Basically its this...

1. Shorten the door.
2. Move the upper hinge mount down, about 1.5", get the dimension from the 3rd door of the burb, take the front inner door skin off to do this, it needs to be modified to match the B pillar anyway (more upright)
3. Move the window regulator and inside handle mount forward, about 1.5", I don't remember the exact number, again get the dimension from the 3rd burb door.
4. Make clearance inside the door for the front window channel (inside door hinge reinforcement)
5. At the front of the door where the door lock would be on the inner skin, replace that panel with one from a passenger side door, this gives the pull lock hole and the proper inside contour to match the B pillar
6. Build the front of the inside door skin to accommodate the front window frame which will also accommodate the front window channel.
7. Use the locking relays from a donor 3rd door to make them fit the 4th door, you can remove the rivets from the mounts flip the pivot arms over and restake the rivets, drill some holes and bolt it in, the lock rod needs to be reversed and so will the handle rod too.

That's most of it...its a lot of measuring, cutting, fitting and welding.

Re: Crew Cab build preview...
 

Rockers while they seem simple can be a pain...I measured my drivers side out on sunday, thought I had it all set to weld, verified the placement last night and welded it in, then when making the rear rocker I found out it is about 1/8" too low at the rear, now I have to take it off and re-weld it. This would not be a problem on a regular cab but on the crew it doesn't line up with the rear rocker and has a noticeable dip in the middle so I have to take it back off, dumb me, I welded it solid and ground the welds flush, I should have just tacked it....it would have save me a bunch of work.

Re: Crew Cab build preview...
 

Pictures...
Lots more welding, in the second pic is a box of 50 cut off wheels I got on amazon, great deal, about $1.40 ea.

Re: Crew Cab build preview...
 

Tonight I welded up the bottom interior of the 4th door, the patch panel for that sucks but if you install it in pieces and massage it before installed it can work, its the worst patch panel sold for these trucks, it turned out ok.

Re: Crew Cab build preview...
 

So the door now has a window that rolls up and down with outer door skin clearance, it doesn't look like much but was a lot of work.
As you can see I also fit the window frame to the rear door.
I will fix the picture orientation tomorrow.
I also made the window channels front and rear for the 4th door, then I fit inner door panel structure from the suburban fake 4th door to support the window rear channel, which also provides access to the inside of the door.
Now the 3rd door and my 4th door inner structure match. It makes it look more finished!

Re: Crew Cab build preview...
 

I agree with you there 100%, it is the worst patch panel that is not hardly close to lining up with the original body lines. Progress is looking good Randy :mm:

Re: Crew Cab build preview...
 

Couple more pictures

Re: Crew Cab build preview...
 

I put a new Key Parts door skin on the 4th door this weekend and am very happy with the fit of the skin. I also finished the interior of the door where it meets the front skin and around the front window hoop, it was a massive amount of welding. Some pictures with door gap pictures and dimensions for jcfcamaro....
Door gap measured above door handle on flat part of skin with dial caliper and above lower body line.
Top .270
Bottom .245
The gaps look good but I would like it a little tighter, the rear on that side is
Top .180
Bottom .148
I like the rear gap the best and think those numbers are ideal. I will move the rear door forward on final fit to even up the gaps a bit.

Re: Crew Cab build preview...
 

I also installed the 396 and put the cab on the frame. The cab install is just to consolidate space with the frame and cab now only taking up one parking space. I haven't lengthened the frame yet, when I installed it I had to block it up with 2x4's and 4x4's because the cab is so long. Looks like a 4wd now, I wish I had the time to convert it to 4wd but I still plan on driving it this summer and that would set me back a bit.

jcfcamaro...if you can zoom in on the rear door gap, I think that gap is the best one of all the doors. Again I am in the range of good gaps and they will be finalized when I bolt the cab to the new frame which I will do before I paint the cab.

Re: Crew Cab build preview...
 

Pictures of passenger side door fit and gap dimentions
Front door gap
top .218
bottom .209

Rear door gap
Top .218
Bottom .209

Re: Crew Cab build preview...
 

I put the seats in and was very surprised at the leg room in the rear. The rear compartment seems so small and everybody knows a regular truck cab doesn't have much leg room. The factory bench seat seems so bulky.

I have been saving a 60/40 seat from a 98 chev truck just incase I need to install it in the rear for more leg room.
The factory rear bench seat doesn't hinder ingress or egress from the cab and looks great. I already have matching off-white seat covers for the buckets and bench seats. I'm really glad I decided to go with buckets in the front, makes it look spacious.

Re: Crew Cab build preview...
 

for cab room reference, my daily driver since 2002 is a 2002 Silverado crew cab and I have sat in the back quite a bit, I think the rear compartment of that truck is nice but a a bit small, I'm 6' even and now weigh about 250lbs, I'm 51 years old.
This cab feels like it has the same amount of room getting in and out and when seated. Its gonna be a comfy cab to ride in.

Re: Crew Cab build preview...
 

3/16" is a good number to shoot for. A lot of people use a paint stir stick as a guide. The factory assembly manual calls for +/-1/8" as spec for panel gaps!

Re: Crew Cab build preview...
 

Very nice work- really coming along! Are you a '66 model? (I am)

Re: Crew Cab build preview...
 

I have never owned the older trucks, thought about it in the latd 80s, there were some neat ones still around for cheap, always to many 72s to fix up

Re: Crew Cab build preview...
 

Cool work! Do you have a plan for the roof? It seems like they taper down as they go forward, so your back section will "drop" in behind the front section, whereas you'll want a continuous piece of some kind...

Not that I have any ideas, just curious!

Re: Crew Cab build preview...
 

The roof has been done on other builds with multiple truck roofs or one suburban roof, i have all that, will be starting that part this weekend.

Re: Crew Cab build preview...
 

Very nice work on your crew cab. Some day after I get a few other builds done, I'm going to build one. It'll likely be mega cab-ish though.

Re: Crew Cab build preview...
 

Thank you.
A friend came by that i havent seen in a while, he said...why didnt you make a 6 door...i never even thought of that. Would be cool though. I only need 4 doors because i like how easy they drive. I do think i will need to find a fast ratio steering box and possibly modify the steering stops for parking lot work. I believe the newer trucks turn sharper at full lock than these old ones

Re: Crew Cab build preview...
 

Dude you have mad skills , looks great , Id like it with a short fleet bed and stock or slightly lower stance , love your seat choices .

Re: Crew Cab build preview...
 

Finally back at it. Building the frame today. I also finally got my lift back, I had my corvette on there for 2 5 years...the lift has sure been handy.

Re: Crew Cab build preview...
 

Couple more pics and my cut plan...only letting me load one pic per post right now

Re: Crew Cab build preview...
 

Weird frame, never seen one without a vin number, it's missing front and under the cab too...

Re: Crew Cab build preview...
 

Frame cut line for front half

Re: Crew Cab build preview...
 

Nice plan there. Corvette you say. What year?