Re: My 78 K15 High Sierra build - Fish Tremble
 

Well, when I left off a few weeks ago, I showed the large hole I had cut in the passenger floor and a patch panel I'd trimmed to fit. It's at least 100 degrees in my shop right now so seemed like a good time to come into the AC with a beer and update my build. I'm going to jump to the finished (almost) picture of the patch panel in and spare you pics of all the ugly holes I burned and had to fill. At that point I decided to tackle just a small patch to feel better about my progress. Somewhere, I got it into my head that butt welds were the best route, but I think I just caused myself a lot of grief going that route with this floor panel. I think a lap joint would have been easier, gone a lot faster and probably turned out better. It won't be seen anyway once I'm done. Didn't realize how fuzzy my magnets had got in the 3rd pic:lol: I've been taking the tops off my welds lately with the edge of a cutoff wheel, which works pretty well. The tools I've got to finish off the grind are either too aggressive (grinder or flap disk), or too gentle (maroon scotch pad thingy on die grinder). Need to find something in the middle that is just right. Waiting to finish cleaning up these edges til I find what that is.

Re: My 78 K15 High Sierra build - Fish Tremble
 

That left me with a hole in this crazy spot on the rounded end of the hump that the seat mounts to. I didn't have a patch for this, so I used the part I'd cut out as a pattern and made my own patch. Too many curves for me to make it out of one piece, so I started with this piece that I could get the bends/curves I needed. It had to have a pretty big relief cut/hole but I'm pretty happy with how it turned out. Don't mind the ugly burn holes. After all the sheet metal welding practice I've had by now, I think that the only skill I'm improving is filling the burn holes I make:metal:

Re: My 78 K15 High Sierra build - Fish Tremble
 

That brings us to today. I made another patch to finish that rounded seat hump area and got it welded in. Got plenty more practice filling in burn holes:lol:, but actually pretty happy with the end result. The last picture is where I screwed up cutting/fitting the original floor panel. The gap is too wide for me to weld, so I think I'm going to have to cut the gap wider, and hopefully more even and make a patch for that. Then I just have to do all the spot welds for the brace that needs to go back in, and to attach the floor to the kick and rocker panels. Oh, there's a 1/4 inch gap on that edge too, so some hammering will be required:metal: Well, time to head back into the oven and get after some of that.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looking good Rick!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Progress has seemed to be at a snail's pace, but at least progress. I'm calling the rust repair on the passenger floor and kick panel done! Finished up from the bottom last weekend and a neighbor helped me turn the cab back upright. Touched things up from the inside today. The big light blob on the inside was a large hump that I had to use a torch and hammer to shrink. The rounded curve for the seat hump will need some filler since I'm pretty sure it will show, but I think I got the shape about right. Started cutting out the rusted driver side floor. Hope that side goes quicker! I know that the welds aren't really cleaned up that well, but I plan to undercoat the truck and lizard skin the inside floor. Then it will be covered with insulation and carpet so I don't think I'm going to really care that it's not ground totally smooth.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Great job so far. Keep up the hard work and it will be done before you know it.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking my build Steelhorse. A year or two probably will be "before you know it" the way time flys at my age:lol: I've been making some slow progress, but with the heat, yardwork and other summer activities my build seems to have slowed to a crawl. Oh, and the mosquitoes come out just as soon as it cools down enough in the evening that you feel like working outside.

I've decided I'm done with metal work on the floor. Did the driver side a bit different (cheated) and just cut the patch to overlap the hole 3/4 inch. Plug welded around the edge and down the braces. Once I seam seal it, I hope it works out as well as the other side that I butt welded.

Now I'm working on the driver cab corner (for the second time). This LMC patch panel seems to be coming up a bit short of making the corner. Haven't figured out what tool will help me reshape that curve without screwing up the patch.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Making progress is always good to see.
On the "filling the gap" I've used a "copper spoon" from Harbor Freight Tools, under $10,
Hold it against the back side of the gap, weld a little hear and there to fill the gap. Weld won't stick to the copper.
Good work keep it up.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Good to see progress! That patch looks hella short from the picture. It looks to me like your going to have to cut the patch to add more material.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Yep, the picture isn't exaggerating. I'd guess that the best place to slice to widen the patch is right on the face of it, top to bottom so that it maintains the line going down the corner of the cab. That's going to really put my welding and grinding skills to the test since it will be right out there for the world to see.

BTW Mike, good to see that you got yours back to a roller. Reassembly should be quick from there and you'll be back to body work before you know it.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Just remember patience and walk away if you have to :lol: When I did my cab corners, I think I had to do that for several weekends.

Thanks! It's a great feeling to be that far along, but I can't believe you just cussed at me...body work....ewe :)

Re: My 78 K15 High Sierra build - Fish Tremble
 

Cab corners are tough. I used LMC on my 72, too, and eventually got the on to my satisfaction, but they still aren't quite right.

Looking good so far. I'm sure you'll get the cab corners figured out. And if you are too cheap to buy the copper spoon, you can attach a scrap of copper pipe to a handle of some sort an hammer the end of the pipe to whatever flattish shape you want. That's what I did, but like Bomp said, they are pretty cheap from harbor freight or equivalent.
Posted via Mobile Device

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for the encouragement guys! I do have a piece of mashed copper pipe I use to back larger gaps and holes. I had screwed up trimming on the passenger floorboard so there was a gap 1/2 inch wide in places, so I ended up cutting the gap so it was maybe 1 inch wide and even all the way across and just welded in another patch.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I absolutely love this build!!! Keep on trucking partner, many of us have been right where you are.

My old dually just picked up a 46 power wagon in Wyoming. From up here in Canada it was a 31 hour behind the wheel trip. Did in in 2 days, the old girl ran flawless. So there will be a day when your love comes to life and makes it good. I got so many looks with the dually hauling the PW, was a great trip.

Here is my next restore, hey, its my first non GM work. So easy on my post ;)

Re: My 78 K15 High Sierra build - Fish Tremble
 

Not going to catch any grief from me about building the Power Wagon. That thing is too cool! I hope you do a thread in alternate tinkerings so we can see more of it.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Got the driver side cab corner done. Didn't end up doing any slice and dice. Decided to work it from the backside of the cab, then massage it around the corner a weld at a time with some tapping to bring it around. Ok, some of the tapping was more like banging, and I missed the gap on a weld or two :lol: It's going to need a bit of filler, but I think I can make this look ok. I'm feeling pretty pleased with myself on this patch.

Re: My 78 K15 High Sierra build - Fish Tremble
 

There you go! Don't you just love patchwork?:uhmk: Looks real good!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Mike. I love patchwork about how you apparently love bodywork. Sorry for cussin' you the other day about that:lol: Actually, I don't mind patchwork at all when it turns out, just wish that were the case more often:waah:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Whoa what a build. Don't you just love how they all start simple and turn into never ending projects or never done haha :D Looking good so far. I don't think I would have the patience for all the patch work. It's going to be so sweet when its all done though!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking in on my build Hoods. I decided to repair my existing cab because I needed the practice welding in patches. In reality, I might have saved myself a lot of time and frustration just finding a better cab to use. So far, practice isn't making me anywhere near perfect, but its possible for something to be both frustrating and fun at the same time, right:confused:

Re: My 78 K15 High Sierra build - Fish Tremble
 

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!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for the welding tips gmachinz. I try to follow that advise, but sometimes easier to say than do I guess. I don't do too badly when I'm welding right in front of my face. Speaking of which, I been making slow progress the last couple weekends. Got the passenger side cab corner in and started on the firewall. Good bit of rust around where the ac/heater stuff and hoses go through the firewall, and even more when I started cutting away some of the metal. Felt like good progress this weekend though. I'll clean the welds up a bit more, but wound up ordering the wrong abrasives for my die-grinder:waah:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Well, I have kept at it in the month since I last posted. Just not a lot in any given week. Finished up the firewall and moved onto the windshield pillars/frame (not sure what they are called). Had to shape the patches using bench vise, pliers, a little hammer and dolly. Not sure what tool would have helped on these smaller pieces, but the curves are tough. I've just rough ground the welds with my cutting disk. Still waiting on my course sanding disks for the die grinder to finish up. All things considered, I think these turned out ok.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Nice build, everything looks great so far! I hope mine will turn out like that! I am just starting on my 79 project, and I had the same question as gmachinz. Are you mig welding or flux core? I need to do a lot of floor and hump patches like you did, but i only have a flux core steup right now. I figure it will burn some bad holes too. Thanks.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hi Stampy - thanks for checking in. I do mig weld my patches, although I've seen threads where the guys used flux core for sheet metal patches. I've seen a LOT more though who say mig is the only way to go.

I have finished the patches for the cab finally, and I'm working on removing all the surface rust. This cab has been bare in Houston humidity for too long! There are so many edges on the bottom of the cab that they keep tearing the edges off sanding disks. These things below work pretty well. They get tore up also, but last longer - just wear a full face mask because there are a lot of flying hard plastic pieces flying off them! I'm still looking for a better solution short of re-blasting.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Your builds going nice man. Do you think you could give me some pointers on patch panel repairs. I need to replace the rears of both front fenders.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks 19silverado77. Sure I can give you tips, but fair warning, this project has been my first experience welding sheet metal as well.

First tip is the google search box at the top of the screen is your friend. Type in "welding patch panels" and select the "67-72chevytrucks.com" dot and you'll get links to a ton of threads specifically on this. Here's an example of a thread I posted asking for this same kind of advise myself.

http://67-72chevytrucks.com/vboard/s...d.php?t=576708

I can also give you a few tips that may not be spelled out clearly elsewhere. When you buy your patch panel, it will likely be much larger than the rusted area you need to patch. You don't need to use the whole patch and probably don't want to for these reasons:
1) Smaller patch means less weld which means less opportunity for warping (but you'll probably get some anyway).
2) The leftover patch material is good for those places where you have to make your own patch. I have more of these spots on my cab than the spots I was able to get a patch panel for.
3) Most important, by cutting the patch down to just what you need, if you screw up you can cut the patch and a little more original metal back out and a new patch will still fit for a re-do.

I probably spend twice as long getting a patch to fit as actually welding it in. If you leave gaps that are too wide, they are tough to weld and generally in my case make the job of grinding, fixing burn holes, etc. bigger than it should have been. If your best effort at fitting the patch still leave some slightly too big gaps, use a copper backer behind what you are welding to help you bridge the gap. Weld won't stick to it, and it absorbs heat helping you not to have burn outs. I use a piece of copper tubing I smashed flat with a hammer.

When welding in the patch, everyone will tell you to take it slow. Make a few tacks to hold the patch in place and then fill in the gaps a little at a time, letting the metal cool before you go back to the same area of your patch. One piece of advise I got was rather than putting tacks in the middle of other tacks, start each tack on the edge of another to help prevent burnout. I'll only put 2 or 3 tacks in a row slightly overlapping the last one and then move to another area. Some may say even that is too much in one spot.

Grinding is where I probably have made the most mistakes. In my own experience, when I do a butt-weld for a patch panel, the metal shrinks in a way that leaves the weld in a slight valley. Not a problem if you have access to the back of the weld because after grinding the weld close to flush you can use a hammer and dolly to flatten the area before finish grinding. The mistake I made was attempting to grind the weld flush when I couldn't hammer it back out and didn't really realize what was going on. I was taking off too much metal on either side of the weld. Then, when filling pin holes I'd end up burning a hole in too-thin metal. I've actually had to cut some of these areas out and patch my patch :confused: The technique I've adopted lately is to take the weld down near to flush using the edge of a cutoff wheel, just moving back and forth on the weld. I have better control than using a grinding disc because for me it is tough to see just what is being ground (likely metal beside the weld) using the grinder. When you get it close to flush, I've had pretty good success using either a flap disk or a 36 or 50 grit roloc disc on a die grinder to finish taking it down.

For all that, I still don't get patches that look as good as many examples you'll see on this forum. I will be using some "kitty hair" filler over my butt welds. It is supposed to resist cracking better than regular plastic filler. It is also waterproof so it will hide the ugliness and fill whatever gaps I left in my weld.

Hope this helps you some. Main thing is read as many of these helpful threads as you can first, and then practice on something else before you jump right into your fender.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks man and ill look into it and let you know how it turns out.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Ok, too cool even here in Texas to spray epoxy primer on the cab, so I've moved to the bed. For the most part, its in pretty good shape except for a couple spots behind the wheel wells, and the bed floor itself is rusted pretty thin. After removing the trim and rails, I started tackling a rusted spot in the bed side. In an attempt to reach a "last page" on my build rather than having each page listed, I'm going to post a step by step of this rust repair.

I'd bought a patch from LMC that actually would replace the entire lower rear bedside, but cut out just a small portion of it that I needed to deal with the rusted area. I used electric shears to cut out the patch. Then I held the patch up to the bedside and used a sharpie to outline the patch, and a cutoff wheel to cut out the bad part of the bed side.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Then I use a "surface preparation" pad on a die grinder to remove paint and expose the spot welds. For the type of spot weld bit I have, I first use a small bit to drill a pilot hole, then the spot weld bit to cut through the upper layer of metal. You can usually tell when you've cut through by feeling a little more give, and rust and dust start coming out of the hole while you are drilling. Then a screwdriver to pry the cut out portion loose, and voila, the bad part is off. BUT WAIT!!! Behind that is another chunk of metal that looks just as bad as what I cut off (story of my life on this build :lol: )

Re: My 78 K15 High Sierra build - Fish Tremble
 

This is where having all the left over patch panel helps. Using a few basic tools you make your own patch. In this case, a couple pieces of angle iron in a bench vice, plus brute strength and a hammer works as an acceptable sheet metal brake. Not shown, but I used the cut out piece as a pattern to cut out and find the right spots to bend in some angles. I use this purple scotch pad kind of "surface prep" disc on the die grinder to clean the rust off the edges of the hole to be patched, as well as to clean up the edges of the patch itself to get clean bare metal.

Then a few spot welds to hold the patch in place and moving around fill in the gaps between the initial welds.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Finally, I used this flap disk on an electric grinder to clean the weld up somewhat. This one is going to be covered, so I'm basically just wanting to make sure no weld is sticking up high enough to interfere with the outer patch. Once it is ground down good enough, I cleaned the whole area with mineral spirits and then sprayed on some self-etch weld-through primer. Final picture is the original patch over the original hole. It is really close to fitting but need just a little more grinding. But, its dinner time and I've had about 1 too many beers to tackle any more on this patch that's going to show so I'll finish it up one night soon :metal: Hope this helps someone that is just looking for a clue as to what is involved, and the tools used.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Made it to a milestone. Rust repair done:ito: At least I think so. Finished up both spots behind the wheel wells on the bed. Other side had a surprise once I cut out the bad spot, so I had to cut even more so I could fix the area behind. I hadn't bought a patch panel for this side so I ended up welding the original metal back in with the smaller patch in it. I think both sides are now ready for a little filler. In fact, that's what is up next. Lots and lots of bodywork.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Last pic.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Got caught back up. Whewww, You've been busy.
Congrats on getting to the body work stage.
Looking good Man, Lookin' Good

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Bomp. I wasn't sure I'd EVER get to this point. The rust just went on and on. I been following your custom chassis work and its looking really good. Not sure I'll ever be brave enough to take on that much customization - basic restores are challenging my talents as it is :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Happy New Year! I've spent part of my holiday/work shutdown time figuring out how to mount nurf bar steps on my truck so my wife can get in. Ok, so my heavy old self is likely to appreciate them as well:lol:

I bought the bars from Dee Zee. They were universal but supposed to fit my application with some fabrication required - understatement of the year!! Between the step up in the frame starting under the cab, and my saddle tanks, the mounting bracket for the rear didn't even touch the frame and the front brackets only had the top set of holes on the frame. Fabricating a new set of mounting brackets for this severely stretched my limited talents in this area:lol: I think I'll be happy with them though after I do some touch-ups.

I'd posted a "need some help" thread on the main 4x4 forum, but got no responses. I'm posting the details of what I came up with in that thread. http://67-72chevytrucks.com/vboard/s...=1#post6445798

Re: My 78 K15 High Sierra build - Fish Tremble
 

Boy do those look nice great job.

Re: My 78 K15 High Sierra build - Fish Tremble
 

One of my favorite builds is BACK!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks guys! Project never stopped, just moving slowly. Here are a couple of the step mounting brackets done. I had been trying to figure out a good way to handle getting my bed on & off and found an add for a device that was a couple hundred dollars. I figured I could build one that worked as well, and it did. Stuck the bed back on the truck to test it out and so I can dial in my tailpipes and get them welded. Felt so good just to see it kind of looking like a truck again that I spent about an hour just looking at it and taking a bunch of pics.