I had a few hours to kill so I spent them in the garage.
Except for filler/finishing work, I consider this cab corner "complete." To get this far I had to clean off a ton of undercoating/tar like substance, and replace the lower rear pillar piece. I am very happy with the results. I'd welcome feedback from anyone on the welds, did I grind them "enough". I ground through a few times so I feel I found the happy medium. I figure a little extra texture will help the plastic filler adhere. Ha!
I left quite a bit more on the inside, which will be covered by carpet.
I am thrilled with how this turned out. Admittedly, I have little to compare to. Does this seem on par to those with more experience?
BEFORE
Here is what the old one looked like. It wasn't so terribly bad from the outside, but still had to go.
As it turns out, somebody repaired this in the past. Both the rocker panel and cab corners were pieces welded over the factory pieces. There wasn't much left of the original cab corner.
AFTER
I finished grinding down the welds and threw a quick coat of etching primer on.
I welded on some grade 8, 1/4-20 nuts so I could sandwich in the rear brace, outer floor, and pillar. From everyone's post on this site, it seems that is the factory solution.
I'm super happy with the door/cab corner alignment. While I was doing this I fit the rocker up at least 30 times, so I hope it lines up well too.
