New Project! 67 Extended cab...

[Rokcrln]

Weeere Baaack! Well I have the extended cab project back in the shop for some finishing touches on the metal work now that blasting is complete. We will be starting with some frame fixes (already done) and then moving on to seat mounts for 2004(+-) extended cab seat's (front and rear flip also finished already). Then the fun begins with the rear extended rockers and cab corner. When this truck was extended back in 67 they used door skins and regular rocker outer for the job. The only problem is when they did this work they just over lapped everything for a speedy job. This has lead to a few problems, first is the panel fitment. If you look at the rear of the door jamb you will see that the quarter panel extends out a bit past the rest of the rocker and door. Also the rear rocker is about 3/8" to low also because they just over lapped everything. All this over lapping has led to alot of rust over the years that we are about to correct. Keep in mind that when these trucks were built by the coach company they were built for work and not to look preaty or last a very long time so with that being said they did an ok job. Also from what I can see of how it all went together it was only about a 3-5 day turn around on each truck.

What I have done to this point is remove both layers of rocker and added inner panel. I also had to cut the quarter panel loose from the door jamb in order to line things back up. I then took a new rocker outer and trimmed it for a perfect flush butt fit. I had to de-bend the rocker just a bit since they always have a slight curve to them to match the door bottom and this quarter is straite. Once it was all lined up and ready for welding I pulled it back apart and cleaned all surfaces to be welded. I also treated the inner structure with Rust Doctor (the same product that the owner treated the entire exterior to after blasting) and let it sit for 20-30 minutes while I was getting other areas ready for work.

Here are a few pics of the tear down prosses prior to welding in the new parts.

Kevin
LFD Inc.

[Rokcrln]

Ok the new rocker is in, welded, hammered and ready to go. The quarter panel is now just how it should be Flush! Time to start on the cab corner!

Kevin
LFD Inc.

[Rokcrln]

What a pain in the A$$. Replacing a cab corner is a breeze when you can get to both sides to hammer and dolly but when it is 30" + away from the door jamb it is just a pain! I had to take one of my cheapo dollys and weld on a 3' long piece of 1" tube so I could work the seam from the out side reaching thru the window with my left hand and hammering with my right.

Kevin
LFD Inc.

[Rokcrln]

Pass side time! Same thing just the other side.

Kevin
LFD Inc.

[smbrouss70]

Man, if I could hammer and dolly without using any hands, I would get a LOT of work done on my Blazer.

[Rokcrln]

Originally Posted by smbrouss70

Man, if I could hammer and dolly without using any hands, I would get a LOT of work done on my Blazer.

What you guys thought I acually did this work my self No way I don't like getting dirty

Kevin
LFD Inc.

[Rokcrln]

Started the roof today, not alot of fun! When this thing was made they cut the cab off just behind where the roof starts to curve down at the rear body seam. This is where they butted the new pan they used for the extention roof and by doing so the roof had a valley right accross the B pillar location. Also their was a large dent right over the drivers head that they filled and filled with bondo. The vally had spots that look like 5/8" deep and the roof dent was about the same. The valley their was nothing I could do to fix this short of re-skinning the entire roof and for a daily driver the owner did not want to go this route. He just wanted it fixed better then it was and try to minimize the amount of bondo needed. The dent I tried to first pull it with my stud gun and that did nothing due to it being streached real bad right in the middle. So next I tried to shrink it and I did about 60 shrink spots and this helped but not enough. Next I sliced a few spots in the roof and pulled it tight and welded them up but still this only got it flat but it still tin-canned.

So my fix for these areas was as follows.
First I did the valley and for this I took a straite edge and layed it accross the valley and marked the two high areasfrom one side to the other. Then I maid a paper templet that followed my marks that I maid with my straite edge. Then I transferd that to a piece of sheet steel and formed it to the curve of the roof then started to tack it in place while double checking it for flatness accross the valley. Once it was fully welded up and ground down I checked it for how it looked for flow and bondo amount and both ended up good.
Next was the dent over the drivers area and I did this one mostly the same but with one major change. I has a compound curve tward the front corner of the cab so I had to pre shape this part. For this I pulled out my panel beaters and sand bag. It did not take to much to get the desired curve that fit the roof. After a few double checks I tacked it in place and sood back for a good look. I liked how it all layed down so I started to tack it in place and the dinner bell rang. I will try and get it finished on friday and start the windshield lip repair and then on to Project Lemon Drop!!

Kevin
LFD Inc.

[krue]

Thanks for the update.

[Rokcrln]

Originally Posted by krue

Thanks for the update.

No problem! One thing I forgot to mention is I coated both the roof and under side of the overlay before placment..

Kevin
LFD Inc.

[Rokcrln]

Well almost done! Finished the roof tonight and started the rot down at the windshield base. We had a donor piece but it would not cover all the damage but some is always better than none. The corner piece I have to make with my shrinker/stretcher. Here is a sample.

Kevin
LFD Inc.

[bucket]

WOW! I know more about this kind of stuff than any of my buddies. They are amazed I even know how to weld. Then I see this kind of thing being done. I don't know squat. Nice work!

[extd56]

Kevin,

The roof looks really good, and it looks like the windshield rot is going to be a thing of the past. My only problem is that I have 2 cool projects and most everything to put them together but which one to work on first before the money runs out and it is back to the paper route.

[Rokcrln]

Easy, get a second paper route and put your grand kid to work! I sware he has got to be the only unemployed 2yr old I know!

Kevin
LFD Inc.

[Hart_Rod]

My vote is 4 the 4 Door, then you can take your friends with ya when you do your paper route!

Rob

[extd56]

Pictures of the extended cab getting some body work done.

[meathead95]

what happened to the 4 door project?

[extd56]

It is waiting its turn, can only work on 1 at a time

[meathead95]

i understand totally. the ext cab is looking great.

[extd56]

Some updated pictures of the cab. Trying to get the body work done and get it in primer. All the tires were flattened to make the top of the cab easier to work on.

[72armyswbtruck]

Man oh sakes alive,
If only I had the skills and the paper routes that paid like yours......
I could get the other 4 door project finished....

[extd56]

I keep the wife working, need to tell her to work some OT

[Yukon Jack]

Continues to look great - awfully excited to see your project in paint.

[68GMC454]

man it looks good..would like to build one one day..but my ol lady says she wont work 2 jobs to support my habit..guess its time to get another ol lady..

[extd56]

Originally Posted by 68GMC454

man it looks good..would like to build one one day..but my ol lady says she wont work 2 jobs to support my habit..guess its time to get another ol lady..

They say it is cheaper to keep them than to trade them in, never know what the next one is like. I did upgrade once and it cost some money but was worth it. My wife lets me play with my toys and does not complain too much as long as she has a spot in the driveway. She has not parked in the garage for at least 10 years.

[extd56]

One more picture from the front of the truck. I am still trying to figure out a color for the truck, nothing too dark of course. I was thinking maybe a light blue, red or yellow. Maybe even a light green color. Choices are tough sometimes.