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My son's build. '72 Chevy

And this is how the right side is starting out. More reproduction bliss!!!

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Well I can't match the radius of the bends with my skills and a vise, but I got it close enough for a piece that will be hidden. So this is what my son will get to see when he gets home.
I quit for now because of allergies from helping my sister move. (Cats)

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So today he got to see what I did yesterday, AND we got the left side done as well !!!!
It sucks that it took 3 pieces to properly build what the repop part was supposed to do, but we both feel better about the end result. We test fit the outer rocker panels to TRY to see what is to come soon and adjust as much as possible. But we also had to attempt to make the door opening correct.

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Been there done that repo metal sucks from everyone! Had same problem on wife's 67. Just do the best you can and move on I say less you got tons of time to make it perfect!
 
Well there has been some progress. It is still a time consuming process, of course.
I don't believe that I posted this.....
He has both of the footwell and lower hinge support pieces done, with the exception of some grinding and finish work!!!!!
We decided to pull the braces out!!!!
Started on fitting the outer rockers and cab corners, decided to order a couple of new ones to help diminish fab time.....
He now looks at the money for different parts as possible time savings, but only after investigation.
He has done more grinding now that the bracing is out, there were a lot of welds to put it back together!!!! We started on the pieces to raise the trans tunnel over the NP241. All of the floors are the same on these trucks, under the seat. It will clear a NP205, but not the 241. He is going to install the tall hump, even though this cab never had it originally. It will have to meet up with what we do to the floor.
He also has the spots of rust below the back window done. There were 3 sections like this which has to get cut out, and some spots where he drilled it, and welded it up. A glass shop Dad used back in the day, put sealer at the bottom of the window, making it hold water.....

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Well there has been some progress. It is still a time consuming process, of course.
I don't believe that I posted this.....
He has both of the footwell and lower hinge support pieces done, with the exception of some grinding and finish work!!!!!
We decided to pull the braces out!!!!
Started on fitting the outer rockers and cab corners, decided to order a couple of new ones to help diminish fab time.....
He now looks at the money for different parts as possible time savings, but only after investigation.
He has done more grinding now that the bracing is out, there were a lot of welds to put it back together!!!! We started on the pieces to raise the trans tunnel over the NP241. All of the floors are the same on these trucks, under the seat. It will clear a NP205, but not the 241. He is going to install the tall hump, even though this cab never had it originally. It will have to meet up with what we do to the floor.
He also has the spots of rust below the back window done. There were 3 sections like this which has to get cut out, and some spots where he drilled it, and welded it up. A glass shop Dad used back in the day, put sealer at the bottom of the window, making it hold water.....

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Not a fan of those surprises

Glad to see some progress
 
So he got the new outer rocker and cab corner. If course they still don't fit perfect, but we will see how much modification they take.
He hung the right door to check stuff out, and we got a reminder how these trucks weren't perfect to start with. The original door doesn't fit the original part of the cab as well as we would like.
Anyway, while he took a break from that, he has worked on the trans tunnel some.
I didn't know about it until he thanked me for starting a filler piece to go it at the rib of the floor, under the front of the seat.
Then he sent me pics!!!
Both sides were like the 1st pic , to get the bump up.

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So with all that John has to keep him busy, he hasn't gotten much done lately, but has been working on the trans hump and doing some grinding on completed welds.
We did make some time to work on modification of the right outer rocker since neither one he had fit the cab AND the door. So more of the chop up 2 parts to make one. No pics of that yet. But the doors got hung on it to do some fitting.
But the floor and trans tunnel is pretty much done from the top, just need to do all of the grinding on the bottom when the cab gets stood back onto it's nose.
But I forgot that he has to see what happens with the shifter for the NP241, so that may mean more work on the hump.

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Spray something on bottom when done like Raptor liner but shoot it at low psi and will hide imperfections!!!
 
Well how about a zombie bump?
There hasn't been tons of progress over the summer, but John has gotten some done.
The left side rocker and cab corner got fit into place, then tacked. He stopped there to get the doors done as he wasn't pleased with how the right door , rocker and cab corner were. So he wants to repair the doors before making changes.
The left door had been dented in below the lower style line at the same time the left fender got replaced years ago. Dad had a guy side swipe him when the truck was only a few years old. There was also rust to deal with.
We tried a dip in an electrolysis solution, which did work a good amount, but didn't get them as clean as we wanted. Keep in mind that the factory didn't put any coating on the inside for rust prevention. Our sandblasting guys finished the job, and did a GREAT job!
Pictures are before dipping, then after, then after blasting. The last pic is looking up into the door.
They got shot with primer tonight.

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He got a job at a local fab shop this spring and got to run the water jet a fair amount. He already had a CAD project from high school that he wanted to make. He wanted an aluminum grille insert for it that looked like factory. He got it cut and assembled to this point and discovered that he should have checked fitment better earlier. He discovered that he was almost 4* off with the "V" of it. So he says that this one is destined to be garage art. He will make a new one. He learned several things with this one, so not a total loss.

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And since the guys at his work have been teaching him lots, he got the idea of having a custom 304 stainless exhaust, so he has been working on it. He wants to be able to pull it , in case the transmission needs to come out, but also have an "H" pipe. So he installed V band joints behind the crossover pipe which will let the pipes come out from the collectors and not have to mess with the muffler connections. He's working on hangers and made a crossmember for the rear shocks to replace the failure prone stock upper mounts.
I realized too late that I should have told him how I would have cut the pipe to jog around the t-case, but it won't be a big visual issue as it's inside the frame rail.
He found parts that were 16 gauge which hopefully will be more durable in a 4x4.
And since the guys have taught John how to tig weld, he has been getting help learning how to weld stainless on his exhaust.

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He got a job at a local fab shop this spring and got to run the water jet a fair amount. He already had a CAD project from high school that he wanted to make. He wanted an aluminum grille insert for it that looked like factory. He got it cut and assembled to this point and discovered that he should have checked fitment better earlier. He discovered that he was almost 4* off with the "V" of it. So he says that this one is destined to be garage art. He will make a new one. He learned several things with this one, so not a total loss.

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Great looking grille. :waytogo:
I remember you posting that in the PAD thread.
Bet he could make a few bucks selling those.
 
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