First, our installers draw a cut line around the inside circumference of the truck cab's back window area, remembering this is double wall material. Basically, the cut line is drawn along the body and door jamb seam lines using a black felt tip marker.
With that done, the next order of business is drawing a cut line around the outside circumference of the small back window. Darrell draws his cut line just a tad above the stainless steel exterior trim mounting holes on the cab to allow for enough material to lap over.
However, just prior to actually cutting into virgin sheetmetal, the Cimbanins first reinforce the lower inside section of the cab's rear wall with three pieces of steel rod in order to maintain the rear wall's shape during the crucial cutting process. With that done, Tim Cimbanin tackles the cab's interior using a Sears Craftsman electric cutter.
Once the interior cuts have been made, it's time to tackle the outside of the cab. Cimbanin starts from the bottom trim line and works his way around the circumference of the truck cab. Once the cuts are made, the small back window panel can be easily removed.
The next order of business is trimming away the excess material from the outside of the donor clip. First, the Cimbanins draw a second set of cut lines, only this time just below the stainless steel trim mounting tab holes so the sheetmetal overlaps when the two pieces are joined.
With that done, the inner sheetmetal is again trimmed to size following the cut lines drawn and cut using the old panel. Once trimmed to satisfaction, all that remains is to fit the new panel into the opening. Obviously, some minor trimming and fitting may be necessary.
Once satisfied with the overall fit, our installers begin tack welding the new panel in place, working center out. Of course, this is followed with final welding, and then it's time for bodywork and paint.
When the job's completed, you'll have a big back window cab you can be proud of at a cost of around $750, new window glass and weatherstripping included.
Shown is the donor back window clip taken from a '55-59 Chevrolet/GMC half-ton. They are b
Preliminary work begins by outlining the inner panel cut area inside the cab....
...Note that the cut line was drawn along the body and door jamb seam lines.
On the outside, Cimbanin runs his cut line on both the upper and lower belt lines just a h
In order to maintain the cab's inner rear wall conformity prior to doing any cutting, Cimt
Tim began by cutting out the truck cab's inner wall using a Sears Craftsman electric saw.