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.... Whoever designed the way the cab metal assembles was an idiot... and further cements the reasons why I'm a Chevy guy
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I agree 1000%. If you compare a Chevy/GMC cab to a comparable year Ford, there's no comparison. Ford likes to single-wall in places that GM will double wall. The GM cabs are WAY stronger structurally. The make-up of the Ford cab is such that it was like it was built backwards. The overlays are completely backwards, like you unfortunately discovered. You wind up damaging good metal on top in order to fix the bad metal underneath because the wrong part is flanged and spot-welded in an area that's completely inaccessable.
I know most guys are brand loyal, done to the bone. I have had the "discussion" with the Ford guys about the comparison of the '60s Ford and Chevy trucks, and have laid out all the differences. EVERY aspect of the Chevy is better, from the suspension, the engine, the transmission, and the body structure. I will give Ford credit in one area, though. Whoever designed their door latches did a great job. You can go to any clapped out Ford in the wrecking yard, and the doors close and latch soooo nice.
Other than that, their trucks are not even close.