[gmachinz]

wow...I commend you for such an audacious approach! Most people-including myself would just drag home a rust free cab....lol. If I can offer a little bit of help-it appears to me after reading all your threads and albeit a little late in the game now for this....but I think you're putting too much heat into each spot weld-which is burning through it-trying to weld to crappy thin semi-rusty metal will also give you a "popcorning" sound as you attempt to weld it as well. Are you mig-welding the repairs? If so, turn down the voltage a hair and increase your wire speed a touch. And, try to place your tacks about an inch apart and give them time to cool before going back in-between them again. I admire your attempt at salvaging OEM panel sand resisting the urge to buy aftermarket! All in all, very good work, sir!