project INCREDIBLE HULK 6.2L with 6L80E

[68 short step]

Originally Posted by Rokcrln

Looking good! When looking down the bottom of the door can you see it flare out? I have had this before but it was the original cab corner that was out and the replacement rocker don't help by having a slight crown to them. I had to cut the cab corner loose and work it out for a perfect door placment. I think it was on the Lemondrop build.

Kevin
LFD Inc.

yes you can see it flare out... this is towards the front, so the cab corner wouldnt have anything to do with it, being towards the front, right?? these pics show where it starts to flare outwards ...

[Rokcrln]

I thought it was the rear of the door for some reason

Kevin
LFD Inc.

[71Hulk]

i realize the door is bowed out but in relation to the front fender the rocker looks to be bowed in???

how does the the vertical gap between the door and cab look?

Dude i didin't realize just how much rust that ol' truck had...looks like your knockin it out!

[68 short step]

Originally Posted by 71Hulk

i realize the door is bowed out but in relation to the front fender the rocker looks to be bowed in???

how does the the vertical gap between the door and cab look?

Dude i didin't realize just how much rust that ol' truck had...looks like your knockin it out!

the rocker in relation to the front fender, is slightly further in...i mean ever so slighty...this isnt gonna be noticeable at all, once the final fitment of the fender is done, and has some body filler makeing slight imperfections 100% smooth...
here is the vertical gap, it too is 3/16 (at least i hope my paint stick is, cause thats my refrence)..
got the rocker pnl welded in, and here are the cab corner pics of it sanded down...it has been replaced once before (see the thin line of body filler), and looks to be fine..

[68 short step]

some pics of tonights progress...started in on the driver side....so far the front "A" pillar, lower foot panel, most of the inner rocker panel, the front cab support, and the lower section of the cab cowl...are the things that are gonna get replaced...also the door seam has rust in a weird spot (seen in pic) that'll get replaced too.this side is better then the pass. side tho, so hopefully it will go quick back together..

[6T9GMC]

Man You Guys Make This Stuff Look Easy, Then I Try It.....#@%4!! Thanks For Posting This Stuff. I Have To Do That Area At The Back Of The Inner Rocker, But My Cab Corner Is Good. I Thought I Was Gonna Have To Cut Off My Cab Corner To Get To It, But Looking At Your Pics I Think I Can Cut Off The Part Under The Rocker To Get To It. You Do Fast Work. It Looks Good!

[lyrikz]

Originally Posted by 68 short step

What are you going to do with this area?? I have something similar, but not that bad.... Plans?

[68 short step]

Originally Posted by lyrikz

What are you going to do with this area?? I have something similar, but not that bad.... Plans?

lots of body filler, then when its painted you'll never know...






noooo, not really ill cut it out, bend a peice to match, then weld it in...that the plan anyway....also isnt that a weird spot to get rust!!!...????

[Hart_Rod]

I would double check the front of the new rocker with a straight edge. I had to slice the ones I put on my suburban because they were about 1/4" off.

[68 short step]

Originally Posted by Hart_Rod

I would double check the front of the new rocker with a straight edge. I had to slice the ones I put on my suburban because they were about 1/4" off.

thanks hart_rod, ill triple chack that...

[68 short step]

getting some metal cut out and fitted....the driver side was equallly as bad as the pass side..the inner rocker, lower kick pnl, cab corner, front support, a section of the rear support are all the peices that needed attention....i got all these peices cut and fitted, ready to weld on...im gonna coat everything i can with the rust bullet rust inhibitor before welding (and not being able to access inner peices) anyway here are a few pics...

[6T9GMC]

Glad To See More Progress. I Am Working On The Rh Cab Corner And Rocker On Mine. Seeing Your Posts Helped Me On Mine.

[Rokcrln]

Wow you sure have alot of areas to "PLAY" with It sure is looking good, just one spot at a time then on to the next!

Kevin
LFD Inc.

[Angelse68cal]

Looking good keep up the goood work and pics coming

[BigSky71]

Great work and great documentation for the metal replacement!

[6T9GMC]

Hey, I Know When You Weld In The Patch Panels You Spot Weld And Keep Going In Different Areas, After Your Done Grinding It Down Smooth What Is The Inside Supposed To Look Like And Do You Grind It Down And Make It Smooth Too, Or Just Leave It?

[68 short step]

Originally Posted by 6T9GMC

Hey, I Know When You Weld In The Patch Panels You Spot Weld And Keep Going In Different Areas, After Your Done Grinding It Down Smooth What Is The Inside Supposed To Look Like And Do You Grind It Down And Make It Smooth Too, Or Just Leave It?

depends on if that spot will ever be seen....in most cases the backside wont be visable, so the weld isnt ground down...but if it will be visable, ill grind it down...
on this truck, its gonna be nice from under it as well as from above, so the underside welds will be ground down and the underside will be bodyworked, too.

[6T9GMC]

Thanks. It's Looking Good!

[Angelse68cal]

Nice work keep the pics comin

[68 short step]

got the driver side inner rocker pnl welded in,and cab support...hung the door to align the outter rocker only to descover the front bottom of the door hit the inner rocker, near the front curve of the angle of the rocker....after wondering why it was doing that and some measuring, i descovered that the ' curve' wasnt the same contour as the bottom of the door, and it also tapered up where i cut it.. futher adding to why it interferred with the door...so i cut out the angle of the rocker and made it so it didnt taper up, and re shaped the curve to match the bottom of the door.....

[71Hulk]

hey don those are some great improvements. Looks like your hard work is beginning to show. Keep up the good work!

side note: is that a whole in the floor?

[68 short step]

yes thats a hole, it was corroded and i blew a hole right through it...im gonna blast the inside of the cab to get the tar off the floor so i can better inspect the floor...but that hole will be fixed and all the corroded and thin metal will be too..

[68 short step]

got some more work to report...
the driver side inner rocker pnl, front cab pillar, lwr footwell, and outer rocker are all welded on... each peice was coated with rust bullet rust inhibitor , inside and out...all went together with minor set backs...the outter rocker needed to move outboard about 1/8" to make it streight and line up with the fender...so i cut it open and moved it out bout 1/8" and welded it back up with a new 'V' shaped metal wedge added in the gap...

[my67chevytruck]

Don/ Hulk,
Is that the outer cab floor extentsion you are using for the inner rocker replacement? LMC part 38-7904 and 38-7905 for $99.95 each. Great looking progress thus far, you give inspiration to us all, even to those that have never done this type of repair before.

[68 short step]

Originally Posted by my67chevytruck

Don/ Hulk,
Is that the outer cab floor extentsion you are using for the inner rocker replacement? LMC part 38-7904 and 38-7905 for $99.95 each. Great looking progress thus far, you give inspiration to us all, even to those that have never done this type of repair before.

yes it is, and thanks