Somewhere along the line the...
Somewhere along the line the cab corners had been replaced, Jason used an Eastwood spot weld bit to drill out the pop rivets used to secure them.
Deep inside the Custom Classic Trucks world headquarters is the Source Interlink Tech Center. There, under the capable supervision of Jason Scudellari, many of the tech stories in the company’s various magazines are created. That’s a politically correct way of saying Jason does the work while the editors take photos, hand him tools and ask dumb questions.
Along with working on just about everyone’s magazine projects, Jason occasionally has the opportunity to turn his attention to his latest acquisition, a ’56 Chevy pickup. In rather rough shape, about the only positive observation that could be made about the cab was that from the door handles up it wasn’t bad.
To begin its resurrection the sheetmetal was sent out for media blasting. Upon its return, it was obvious that a number of patch panels would be required and that some poorly done repair work would have to be corrected. Undaunted, Jason thumbed through the Brothers Truck Parts catalog and found everything that would be required to bring the cab back to pristine condition:
|DHRP900 left|| lower door hinge repair panel
|DHRP900 right|| lower door hinge repair panel
|LDH8900 left|| lower door hinge brace
|LDH8900 right|| lower door hinge brace
|FRP5900 left|| floor pan with toe board
|FRP5900 right|| floor pan with toe board
|FDPR900 left ||door rear pillar
|FDP900 right|| door rear pillar
|LCC5900 left ||lower cab corner
|LCC5900 right|| lower cab corner
|ICC5900 left|| inner cab corner
|ICC5900 right|| inner cab corner
|ISPR900 left|| inner step plate and rocker
|ISPR900 right|| inner step plate and rocker
In addition, Jason turned to the Eastwood Company for a couple of items to help the process:
|Spot-weld removal bits|| 19004
|Black Anti-Rust paint|| 160312
At one time saving a cab that needed this much work was way over the head of anyone but a very experienced and skilled metal worker. And if someone like that could be found, the labor rate to make those repairs would likely be far more than the end product would be worth. But two things have changed that—readily available patch panels and wire feed welders.
The Brothers patch panels are made from the same gauge material as the original body with all the correct contours for specific areas eliminating any trick metal forming. Wire feed welders like our Lincoln (Power MIG 180) are easy to use even for beginners, so rescuing a rusted cab is well within the realm of a do-it-yourselfer.
With time, patience and the necessary patch panels a rough truck can be brought back to life. Just cut carefully, keeping in mind it’s easier to take a little more off the body to make a patch panel fit than to add it back on. And you’ve probably heard this a million times—weld a little at a time to keep from warping the area out of shape. Then, when you’re all done comes the really cool part—you can say “I did it myself.”CCT
A delicate touch with a cut-off...
A delicate touch with a cut-off wheel was necessary to slice through the tack welds holding the patch in place. The corner patches had been laid over the top of the adjacent panels, which meant lots of body filler was required to blend them together and cover the rivets.
There was considerable ugliness...
There was considerable ugliness under the patch panel, and the other side had the same issue—a patch panel covering rust rather than replacing it.
With the right side panel...
With the right side panel completely removed the extent of the rust was obvious. Because moisture settles in these low spots, damage like this is not an uncommon condition.
Before the step plates, rockers,...
Before the step plates, rockers, and portions of the floor were removed temporary braces were installed to maintain the cab’s shape.
Additional braces were added...
Additional braces were added in the door openings.
Jason used the Tech Center’s...
Jason used the Tech Center’s Lincoln plasma cutter to make quick work of cutting out the steps.
There is a brace behind the...
There is a brace behind the center of the step well. Jason was careful not to cut it off.
The remaining portion of the...
The remaining portion of the step well was removed from the brace.
After wire brushing to remove...
After wire brushing to remove loose rust the brace was covered with Eastwood Anti-Rust paint. Once the step is replaced this area won’t be accessible.
The rear corners of the car...
The rear corners of the car were in rough shape. Jason positioned one of Brothers’ inner repair panels to mark where the body would be cut.
Rather than overlap the panels,...
Rather than overlap the panels, Jason took his time to trim the body precisely and butt the new and old. Note the factory spot welds have been cut with the Eastwood bit.
With the sheet metal removed...
With the sheet metal removed the body brace was cleaned and coated with Eastwood Anti-Rust paint.