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Old 05-07-2019, 11:01 PM   #51
EagleScreech
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Re: Wampus Cat

Awesome pics and info here. Thank you!
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Old 05-07-2019, 11:02 PM   #52
roll_the_dice
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Re: Wampus Cat

Thanks for the great seam sealer write up...I am doing mine in about 2 weeks! This is perfect timing!
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Old 05-09-2019, 09:41 AM   #53
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Re: Wampus Cat

nice fab work. keep the pics comming
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Old 05-26-2019, 02:56 PM   #54
TxCajun
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Red face Re: Wampus Cat

Work Shop Electrical

I finished the assembly of the steel building workshop back in November 2018, and have been using it with just two 100' extension cords running from the house while I worked out the electrical design that I wanted and saved up the dollars.

My city electrical permit was approved in early May, and we installed the electrical at mid-month. I ran 220v power from the main panel at the front corner of the house, through the attic to the rear corner of the house, then dropped down the outside of the house to the underground run for the shop.

The area where I live is solid limestone, so we rented a rocksaw to trench 24" deep for about 96'. The limestone is fairly soft and the trenching took about half a day.

In the shop, there is a subpanel that breaks out two 220v circuits for an air compressor and a welder, and multiple 110v circuits to run outlets all around the perimeter of the shop, switched power to the ceiling for lights, switched power to the ceiling for fans, and non-switched power to the ceiling for drop lights. I also have a switched security light circuit outside and covered GFCI receptacles outside.

The install passed the building inspection, and I've been enjoying not dealing with extension cords and tripped breakers for about a week.

Next up, back to cab floor rust repair. ;-(
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Old 05-31-2019, 10:13 PM   #55
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Re: Wampus Cat

Floor Rust

Somewhere in the past, someone had laid bondo and fiberglass on the sides and front of the cab floor to cover the gaping rust holes. At one point I had thought about just leaving this so that I could get the truck back on the road, but after completing all the rust repairs on the roof I couldn't bring myself to leave the floor with this mess, so I started poking at it.

It appears that they slapped this bondo/fiberglass mix on top of the dirty and rusty floor with no preparation, so it was just a crusty mess. The first picture below is about a fourth of the slabs of fiberglass that popped off. Once the loose stuff came up, I used a side grinder with a wire brush cup to remove the rest. It was a dirty, itchy mess.

The second and third pictures show the rust on the driver side floor and the huge hole where the gas pedal was mounted in some of the fiberglass.

The fourth and fifth picture show the passenger side floor and the top of the passenger side rocker panel.

The cab appears to have a thin layer of undercoating on the bottom, and because both the roof and windshield leaked, it appears that the cab floor rusted from the top down (or inside to out).

The good news is that the “A” pillar structure appears intact and the rocker panels are solid except on the top.

I plan to fabricate the patch panels for repairing the floor. I bought a Harbor Freight bench top 30” metal brake for about $50 and a Harbor Freight 2 inch tear-drop mallet for about $8 for doing this. I already have some body hammers and dollys.

I plan to use some of the leftover inner roof panel material (from the Craigslist roof that I bought for roof parts) to form some of the patch panels (it appears to be the same gauge as the floor). I also bought some 18 ga and 20 ga sheet metal drops at a local metal supply shop which sells drops by the pound.
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Old 05-31-2019, 10:35 PM   #56
TxCajun
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Re: Wampus Cat

Floor Rust 2

These are some in-progress shots. My brother is in town visiting his son and has been “enjoying” playing with the metal brake and pounding/fitting panels with me. Big thanks!

The first picture is a panel being cut and formed for the passenger side floor. I don't have access to a metal roll former for making the stiffener channels for the floor, so my brother came up with the idea for cutting these parts from the leftover inner roof panel that already has some of these channel features.

The second picture shows some of the repair panels tacked in place on the driver side floor.

The third picture shows the formed piece that will be fitted to the top of the outer rocker panel on both sides of the cab. It had to be formed in two pieces because it was too long to fit in the metal brake, but we were able to create a pretty good reproduction of the flange where the door weatherstrip mounts.
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