Dealing with roof and A-pillar rust through
 

Looking for some skilled input for someone(me) who has lots of tool and woodworking experience, but not a lot of metal work. I am working on a cab for my dad's 69 C10 LWB. Looking for this to be a driver, not a show truck.

The original cab is rough in lots of places. I picked up a titled cab with very little repairs needed in the floor and firewall. But when I pulled the glass and started poking around, I found rust from corner to corner of the inner header. There is one hole in each of the A-pillar and roof on the driver side. Also holes in the top of the passenger door opening.
The seller made it a package deal with a non-titled cab as well. I haven't removed the glass and poked around on this one yet, but there are no signs of rust rot in the roof. I'm considering a top swap, but hate to cut up a decent cab (non-titled) that I intended to sell.

What advise and direction would you give with these options:
1. Buy the inner header patch panel, and then cut and replace other holes with patches. What's the best way to deal with the A-piller and roof holes? Would removing the roof panel be a good idea for treating the hidden rust?

2. Cut patch panels out of the non-titled cab.

3. Doing a top swap. Makes me nervous, but think I can make it happen with a couple buddies and scouring the helpful posts here. :eek:

Also, are there any good threads for dealing with the seams around the windows? I've seen some pics of trucks where those seams have been smoothed out. Curious how that was done--weld, fiberglass, combo of both, etc.

Thanks for your helpful suggestions.

Re: Dealing with roof and A-pillar rust through
 

Sad thing is ..that's just the rust you can see ..I'd just about guarentee itll be way worse on the inside..
My 2cents.. maybe option 2 and 3 , or I'd find another cab..
If you've never dealt with thin gauge body panels before ,this probably isnt the piece to learn on
Can you get a title on the good cab?

Re: Dealing with roof and A-pillar rust through
 

You have to ask yourself a couple of questions .
1) can you get a title for the good cab you have ?
2) do you have a welder and the metal working tools your going to need ?
3) do you have the dry space to take on a major project ?
4) what's your time frame ?
5) What is your real budget ?

Have you looked in your area what a NICE 69 longbed is selling for ? I've been rebuilding muscle cars and trucks for myself and customers since the 1970's and there has never been a time it has been as expensive to rebuild a classic as today . :smoke:

I'm not trying to talk you out of it just wondering if you've considered everything that's involved ?

Re: Dealing with roof and A-pillar rust through
 

Post up some pictures of the whole truck including engine / interior etc/etc/ :smoke:

Re: Dealing with roof and A-pillar rust through
 

Thanks for the responses and questions to consider.

It's a bit of a Frankenstein, but it was my dad's, so there's a lot of nostalgia at play. Engine is a 400 out of a mid-70's Impala, 71-72 bumper on 69, converted to auto, etc.

I have three cabs right now: #1 Original cab with major rust from top to bottom, #2 Titled cab with rust in the roof as described, but very little down low, #3 Non-titled with solid roof, but a good deal of rust in the rockers, floor, rear cab supports, etc

Here are a couple more pics of the truck as it runs now...

Re: Dealing with roof and A-pillar rust through
 

Build a rack with wheels to set cab #2 on while your rebuilding it , Don't take the running truck apart until your finished with the cab , Do whatever upgrades to the running truck while your rebuilding cab #2 , power steering /suspension/wheels and tires / bumpers ? When cab #2 is done just swap cabs . You can always buy new fenders/bed/hood but solid cabs are hard to find . I think we all have seen where someone strips the truck down to the frame and for whatever reason whats left after they can't finish it get's sold off as parts or a project . :chevy:

Re: Dealing with roof and A-pillar rust through
 

On it!
I'm pretty stubborn about continuing this project before my dad passes away and determined to learn some new skills. :chevy: