Re: Orson the 49 GMC ~ Chris C.
 

Then the buckets were checked for a perfect fit

Re: Orson the 49 GMC ~ Chris C.
 

Then finally they were welded and ground. Next we’ll use all metal filler to smooth the transition.

Re: Orson the 49 GMC ~ Chris C.
 

Alex obviously has much to learn about the art of body fller. But it’ll turn out.

Re: Orson the 49 GMC ~ Chris C.
 

we did the initial fill with All Metal and then finished in Evercoat

Re: Orson the 49 GMC ~ Chris C.
 

looking great!

Re: Orson the 49 GMC ~ Chris C.
 

Thanks joedoh

Re: Orson the 49 GMC ~ Chris C.
 

Alex has finished the frenched headlights

Re: Orson the 49 GMC ~ Chris C.
 

more pics

Re: Orson the 49 GMC ~ Chris C.
 

They look great. Having used this kit in the past the the adjusters for the headlights suck (at best). You might consider reworking that so you can adjust your headlights.

Marc

Re: Orson the 49 GMC ~ Chris C.
 

Good point

Re: Orson the 49 GMC ~ Chris C.
 

The problem is the plastic rings that hold the headlights. When you screw in the adjuster it simply warps/flexes the plastic ring so the headlight doesn't really adjust. Don't get me wrong I love the way they make the front ends look on AD trucks but the functionality aspect killed it for me.

Marc

Re: Orson the 49 GMC ~ Chris C.
 

DAng guys, I'm gone for a month and come back to an almost finished project. Really makes me look lazy when I took 2 years to do mine haha.

Just a thought on the welding....looks like the welder is maybe set too cold? I'm no expert, just saw similar welds when I started out with my MIG140 before upgrading to a 220v mig welder.

https://67-72chevytrucks.com/vboard/...1&d=1588345710

Re: Orson the 49 GMC ~ Chris C.
 

yeah Alex is still learning to weld. You should have seen when he first started out!

Re: Orson the 49 GMC ~ Chris C.
 

This is the sunroof it started with. The issue was that weight of the glass caved the whole roof flat, so we had to replace the whole thing.

Re: Orson the 49 GMC ~ Chris C.
 

After tracing the patch then accounting for the 1” flange we were going to utilize. The roof was cut away.

Re: Orson the 49 GMC ~ Chris C.
 

The patch was fitted into place, then Cleco's were used to hold it in place for welding. Notice, no 90* corners. They are prone to cracking so near to a compound curve in such an expanse of sheetmetal.

Re: Orson the 49 GMC ~ Chris C.
 

Then we welded 2” at time, moving 2'. So as not to warp the sheetmetal. The result? A nice curved factory looking roofline.

Re: Orson the 49 GMC ~ Chris C.
 

Roof patch is all welded in. Started grinding. There is some heat warpage in the rear, so I ordered a shrinking disk. $120, but I’ve been looking for an excuse to buy one. One can never have too many tools!

Re: Orson the 49 GMC ~ Chris C.
 

The sunroof delete looks great...nicely done.

Marc

Re: Orson the 49 GMC ~ Chris C.
 

great work! big panel replacement like that is no joke

Re: Orson the 49 GMC ~ Chris C.
 

No doubt! Thank you!

Re: Orson the 49 GMC ~ Chris C.
 

This is what we started with. I have circles cut from 18ga in serval key sizes for patch work. The circle is then shaped to match the curvature of the surrounding pastel and welded into place.

Re: Orson the 49 GMC ~ Chris C.
 

Then it is ground down and finally bodyworked. Remember, the more time you spend on panel fitment, the less you’ll spend on bodywork.

Re: Orson the 49 GMC ~ Chris C.
 

The floors required a lot of attention, I put Michael on this

Re: Orson the 49 GMC ~ Chris C.
 

Alex is installing the new 4x4 diff, flipping the springs, drop blocks, new shocks, and wheels.