CK5
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83 k10 shorty - rust repair

It always gives me an eerie feeling welding those cab corners by the tank. :weld::grind::yikes:...... I've always covered them and haven't blown myself up yet.
Any advice on the cab corners? I've never done them before and would gladly accept any tips.
 
I'm sure there is a bunch of different ways to do them. I always place my measurements of the new piece on the cab using a marker and automotive tap.
Put some plywood over the tanks just for piece of mind.

Just be careful not to over cut.
 
Depending on how bad the cab corner is rotted out. I have modified the new piece to make it smaller so that there isn't as much cutting and welding on the cab. Saved a bunch of time with Bondo and sanding.
 
Got the driver side cut out. Now I am trying to decide how I want to address the inner panel and what to do about it. Feel free to post up any ideas in my thread in the garage.

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Here is what I did to take care of the rust in the door jamb, where the cab corner spot welds too. Cut a piece out of an aftermarket rocker I had. Now if I can just get the new cab corner to fit with it.

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Driver side cab corner is welded in! I ended up making a triangle piece out of some 16ga I had laying around and welded in to replace the rusty area of the inner CC. Then after a lot of minute cuts and a little grinding here and there I had the CC fitting pretty good, so I welded it in. It fit ok but I had to hammer/dolly it in some places to get it right. Overall I am proud of my work, guess that's what really matters. For my first time doing it I think it turned out well. Still have to lay filler over the seams and stuff but it's coming along. So close yet so far. It's amazing how much time one must put in to such a small amount of body work to get it right.

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Haven't updated this thread in a while but I am slowly making progress on the passenger side cab corner. It and the inner corner were rusted worse than the driver side. It's being a little more of a bitch to get right but I'll get it. Hope to have it done by the end of the weekend. Here's where I'm at as of now.

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