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Nice progress! It's looking realy good!

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Coming along nicely!

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TURNED MAJOR CORNER...at least in my view. Just finished welding in the passenger lower hinge patch. Got lucky, just needed to do the lower bolt and recessed area below. Drivers side was another story, used all of the patch panel, had to drill out a bunch of spot welds, etc.

But this finishes the stressful "make sure everything is just right" patching and welding. Two cab corners and two hinge pockets. Now its on to the fun stuff, bondo, skimming and blocking for paint.

I'll post pics later this week...

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Here are updated progress photos: The inner panel I fabricated for the drivers side, it got welded to the original from the back side. Photo of the backing for the patch panel. I thought it was pretty slick to cut off a inch or so from the patch panel just above my infill cut, then screwed it to the original, screw the patch to that, adjust the gaps and alignment then welded. Photo of the panel primed, bondo will take care of the rough spots, it looks like the maximum thickness need to make it smooth will be less than 1/16". Drivers side lower hinge before and after cutting out the bad and rust treating with POR15.

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This shows the drivers side hinge welded in and then primed after grinding. Passenger side were the lower bolt recess was replaced, with the hinge installed to check alignment, its right on. Saturday night I had a light bulb moment realizing that the cab corners would be open to the atmosphere unless I closed the opening at the inside corners. I remembered that before I took it off the road there was a lot of exhaust fume smell, now I realize with the mufflers dumping right behind the cab the exhaust was leaking up through the rusted out inner corners. I made a cardboard template, transfered it to metal and spot welded it in. I picked up some 3M body seam sealer at the body shop and will seal all the seams for a air tight fit. Sound insulation and carpet will finish it up. I'm also sealing all of the seams under the cab before I under coat it.

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Looking good OrrieG. I like your idea of sealing the inside of the cab.
Kim

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Looking at it I don't know why the factory did not. Anything that drops or flows down there is trapped. I cringe when I remember the times coming back from hunting or getting wood and just hosing it down, it never had carpet just rubber mats. I plan on using the truck and its one less thing to worry about.

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I like the idea of "using" your truck! Why else spend so much on a old vehicle? I think it's a crime to see them all shiny in a garage and not on the street. Just my .02

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My goal is to have a new 1959 Chevy 4wd truck with upgrades like PS, Power Disc Brakes, AC that is as nice as a new truck inside. I know it will still ride like a 59 but it will also be easier to maintain and something I can drive for another 25 years and fix if I have to. No dependence on computers and expensive techs to work on them. Bed is going to be Rhino coated metal so I can haul stuff. I've had 12 old cars and trucks that all have been daily drivers, no trailer queens. I respect and admire those that do that level of work, I just like driving them too much!

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I always enjoy the looks I get from people when I'm driving my older car. It makes it all worth while.

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Looks real good - my cab is gone in all the same spots as you have identified - about same condition by the looks of it. Pretty darn good shape actually! I like the idea of sealing the cab also and in fact have heard of people not even using the inner cab corner pieces when doing so. Does that sound or look desirable after your recent experience with the cab corners - Not using the inners that is?

I also plan on driving mine thus the 1980 SWB frame underneath!

56hotrodred

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The inners add a lot of rigidity and will keep them from moving and flexing at the welds between outer old and new. Also ties in the area at the door lower corner and step to keep that from moving and affecting door fitment. Mine is a fleetside so the corners will be relatively protected. Also they help seal the cab from the elements. FWIW I had about 4-6 hours in each inner side with cutting out, fabing, welding grinding, preping for POR15. Removing, fitting, welding and grinding the outer was about another 6-8 using die grinder with cutoff wheel and 4" grinder. I don't have a plasma cutter. You will need to see if there are any issues with the inners and the 80 frame. Good luck, once you get started its not that bad, I've been aggrevating over this for a year!

Tonight got the radio outlet repair ground down and installed the second infill piece. Oh and picked up my Sidewinder winch I lucked into. Comes complete with extra motor for $150!

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After looking at your pictures again I was looking at my cab corner areas and have to agree. I will replace the inner and the outers along with the step. I actually have all these parts already and hope to take to body shop - not too sure if I want to tackle it. Yours sure turned out nice!

The cab has been sitting on the 80 frame for a while. The 80 frame is exactly the same width as the original frame so no problems with lower portions of rear cab corners hitting. The only real fabricating is the front cab/frame mounts & the radiator mounts. I should be able to pick up my modified front mounts next week and try it all out. Then I will pull it all apart again to work on cab & frame over the winter. Tonight I built a rolling wooden frame to place the cab on and move it around in the shop independently of the frame.

56hotrodred

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I mulled on mine for over a year, body guy wanted $250 each for corners and hinge pockets, 1K total. I had the parts, economy is kicking my cashflow so I decided to just do it figuring worst case is I screw it up and all I'm out is the time and cost of panels. Biggest thing is to over cut the patch and trim it in very small increments, like the thickness of the cut off wheel to get a good fit. I backed my joints because I'm still not very good at the butt welding without backing. Also try and get three alignment points that two are not in the same direction vertically or horizontally, if the triangle points align it has to be right. Good luck.

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SCORE FROM CRAIGSLIST. Couple is moving out of state, no room to haul these. From an 05 Yukon, leather, like new, $100.

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That is the 2nd set of seats from a Yukon I have looked at today in one of these trucks. I really like the looks of them especially with the seat belts built in. Are these the 2nd or 3rd row seats?

I was hoping for buckets so I can build a console and have been mocking a few things up - at least ideas - with some leather buckets I got for free out of a Jeep Grand Cherokee. What has been bothering me with them is the fact that they stick up pretty high in the big back window. I love the back window and do not want to block any of it off.

Are those blocks of wood putting the seat at about the right height?

56hotrodred

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They are the third row seats. They are two separate pieces set up to sit together, there is a middle lap belt. I like the third row because the back is lower. Big factor was the built in shoulder belt. As they sit the main back is about back window sill height, the kick up for the seat belt is hidden by the cab corner. On a big rear window cab you would see it. The height is close, I am not doing an fabricating until I get it back on the frame and can play with the steering wheel (74 truck tilt). I am also going to play with separating them and seeing if I can come up with a custom center console, the factory ones for the front seats look too wide.

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I am going to have to look way closer at these seats. I wonder if they could be split and then get a Yukon matching centre front console and narrow it up to fit in between. I think narrowing something like that would be doable and you would end up with a sweet matching set up.

If the height was close or even a little above the back window sill that would still be great. Let me know at some point if it can be split. If you get a chance and the next time you have the seat out could you take a couple of pictures of the seat from front and back - straight on?

I am thinking on Flaming River or Ididit steering column but am no where near dropping the $$$ on that yet.

Thanks for taking the time.

56hotrodred

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They are two separate seats. I've packed mine away in the attic for now, here is a photo of same with fabric.

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Thanks a lot. I also did a bit of search on ebay and saw some real nice ones with a bit of a console, cup holders, seat belts. They are separated a bit more and would also work real well. I am going to make a point of visiting a few auto-wreckers and looking a bit closer at the variations available for the Yukons, Tahoes & similar vehicles.

56hotrodred

Lots to think about when I get to that point.

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I figure I can go with these and if I want to change it is easy to do.

Progress this week end was hammer and dolly work and started the filler on the cab. I sure wish I had been more careful tossing the firewood, construction debris, bricks, etc. when I was using it as my utility rig!! Lots of small dings under the window, it looks bad but is basically a skim coat.

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Coming along nicely!

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i like the seats.. yeah ive missed the bed a few times on my old trucks.. but have only broken one rear window, and that was a rock slung from my weedeater..

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UPDATE: Finally almost have the cab exterior done. Also fixed the radio hack job that most of these have, welded in a little patch panel, ground it close and used a little plastic to get the final shape. Not perfect but close. Also sanded the cab interior and got the first coat of primer on the dash, except for the radio holes it is mint, just needs blocking, the previous owner had hand brushed dark blue enamel on the upper dash! Also I filled the gas filler hose, in the photo is the last (hopefully) skim coat of plastic. Enjoy, I am.

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The dash turned out great! Looks like prime and paint are in the near future!