Re: 1968 C10 Stepside Restoration Project
 

More BEFORE and AFTERS....

Re: 1968 C10 Stepside Restoration Project
 

...and more...

Re: 1968 C10 Stepside Restoration Project
 

...and more...

Re: 1968 C10 Stepside Restoration Project
 

...and more...

Re: 1968 C10 Stepside Restoration Project
 

So, I am about to undertake what will likely be the most difficult repair of this build. The area up under the dash leaves little room for working. I will need to cut out the bad metal and replace it with good metal. Cutting, prepping, welding, and grinding will undoubtedly be a challenge. Here is what I am facing:

Re: 1968 C10 Stepside Restoration Project
 

As you can see the damage is relatively close to the dash mounting bolts. My primary concern is cutting out the bad stuff without mauling the good areas directly adjacent to it. While I will be using a grinder and sawz-all, my worry is cutting too deep or too far.

Repairing using an old inner fender seems to be the best bet, the inner fender has significant curves built into it that would make creating patch panels a little easier.

Re: 1968 C10 Stepside Restoration Project
 

You may find it much easier to pull the dash to repair those sections :chevy:

Re: 1968 C10 Stepside Restoration Project
 

I agree with Grumpy. Drilling out the pinch welds on the dash will save you a bunch and maybe finding a donor cab with that section the is good would be a good way to go. You have it down and are doing great work so either way you will get it done.

Re: 1968 C10 Stepside Restoration Project
 

I agree with you, but unfortunately there are no donor cabs in my area available that I can rob from. I'm going to see what I can do without cutting the dash out. I know that is not optimal, but I gotta do with what I have. My dash is in really good shape and I don't want to risk ruining it.

Re: 1968 C10 Stepside Restoration Project
 

Well I'll give you credit for doing all the work to save that cab , To bad your so far away ( about 350 miles ) I have a few parts cabs I'm using for my builds that I found when they were still cheap . a few bolts and some spot welds to pull the dash could save you a ton of time and a better result in the end ... :smoke:

Re: 1968 C10 Stepside Restoration Project
 

contact member heehawracing , he's down your way and may have what you need ? :chevy:

Re: 1968 C10 Stepside Restoration Project
 

Thanks Grumpy, I appreciate the lead. If I find I cannot get things how I want without pulling the dash, I will look at removing the dash and contacting Heehawracing.

BTW, I did do a test fit of the carpet yesterday...

Re: 1968 C10 Stepside Restoration Project
 

Just found this thread, awesome work man. following

Re: 1968 C10 Stepside Restoration Project
 

Thanks, I appreciate it. I am really grateful to all those on this forum who blazed a trail for me to follow on my build, as well as those like Paulk C10 and Gibson63 on YouTube. Those guys taught me a lot.

Hopefully I can get this cab finished up in the next month or two.

Re: 1968 C10 Stepside Restoration Project
 

So, I decided to drill out the spot welds and remove the dash so I can repair the area under rhe dash that is rotted out. Did not take long, I used a 1/8 drill bit to make a pilot hole (not really a hole, just drilled into the first layer of metal) then followed with the new bit I picked up thanks to a wise member of this forum who shared.

So once drilled out, I used my putty knife and separated the dash from the cab. Actually separated rather easy. I left one bolt in on each side so the dash so the dash wouldn't just fall.

Once repaired, I will apply the epoxy primer and Lizard Skin to ensure good coverage up under the dash.

Re: 1968 C10 Stepside Restoration Project
 

Here are photos of the process.

Re: 1968 C10 Stepside Restoration Project
 

The last photo above is showing that you also need to drill out the two spot welds outside to the left of the 'seam'...right of the seams on the driver's side.

Re: 1968 C10 Stepside Restoration Project
 

Finally, after removing the two bolts, the dash is free.

Here is a better look at some of the damage. I had already started cutting out what I could with the dash in.

Second photo I have cut out some more, wire brushed, and applied Rust Mort.

Re: 1968 C10 Stepside Restoration Project
 

So, in my attempt to recreate a period correct ranch truck similar to one my uncle had on his dairy farm, I decided to add a Unity GM spotlight. I picked up a really nice used spotlight off of eBay and was happy with how nice it was. All I need to do is replace the wire...easy-peasy. The bracket I ordered separately from Unity, it is the left handed Kdriver side) 202 bracket.

Re: 1968 C10 Stepside Restoration Project
 

Good job on the dash removal! I’m glad you decided to go that route, it will help you out , a lot!!!i have removed a couple, only hassle is, all that drilling...
Great rust repairs, you’ve accomplished!!! You’re a great inspiration for the rest of us!!!

Lol, looking for are to the “after” pictures of the inner dash repairs!!!
Carry on, man!!!

Re: 1968 C10 Stepside Restoration Project
 

I got to learn how to weld with my truck as well. You had a lot more and it looks great. Rock on sir. :metal:

Re: 1968 C10 Stepside Restoration Project
 

I had zero welding experience before this build. YouTube has been a great teacher! I greatly appreciate the positive comments from everyone. It really helps to motivate me.

Thanks!

Cheers-

Re: 1968 C10 Stepside Restoration Project
 

So back to repairing the rust on the area up under the dash. Because of the compound curves, this was a tricky patch panel to create. Fortunately I keep an old inner fender around for that purpose and it came in handy. But the panel I am putting together will actually be several pieces when it is all said and done.

The largest panel was the most difficult to create and that is now welded in. I just need to get my welds ground down a bit more...they will not be flush for added strength and besides, no one will ever see it unless they remove the dash again. The gaps up under the windshield opening will be sealed with seam sealer.

Re: 1968 C10 Stepside Restoration Project
 

The outside area was easier, but time consuming because I had to make several parts and weld them in place, again because of the complex bends and angles.

This looks ugly now, but it will get massaged down into a nice seamless look. I wanted to somehow eliminate the seam here anyway just to prevent future water intrusion which leads to rust.

Re: 1968 C10 Stepside Restoration Project
 

I just filled those areas on with weld on mine. I welded some then ground it down, then welded more ect... until I had a nice smooth finish. Good looking work your doing.