Wow,.....just wow.:thumbsup:

This is one cool project!

I agree with you Tone. This is just way too cool!!

I'm definitely getting a pullmax after I move out of my parent's house.

:D

I love you pros that show us how the metal work is done, even if a bit discouraging. I shape the metal okay and get good alignment, but still get a lot of shrinkage and even after flapping it you can definitely tell that something was joined. Always amazes me to see the two pieces joined in bare metal and not even be able to tell they were welded.

What do you guys use to coat the inside metal pieces you replace to keep it from rusting again?

We normally use weld-thru primers. In this case we removed the entire inside panel from both sides of the truck so we could access the back side of the new panels that we were installing. The entire inside of the panels will be metal prepped and primed later on.

More progress on the truck this week. We finished the passenger side door metal work, installed the new inner and outer rocker and patched a few small holes in the floor. Then began on the firewall by cutting out the original sides and fabbing new flat sections.

http://i563.photobucket.com/albums/s...ture221922.jpg

http://i563.photobucket.com/albums/s...ture221924.jpg

http://i563.photobucket.com/albums/s...ture221935.jpg

http://i563.photobucket.com/albums/s...ture221957.jpg
The center recess was then smoothed and holes were filled. The firewall was final welded and metal finished. I'll try to get a few pics of that next week when we can open the hood again.

On the rear of the truck, we have the upper and lower tail gate fitted. On the upper portion we removed the stock supports that are pretty weak and rattle around. We pocked the tailgate hatch and installed gas support shocks.

http://i563.photobucket.com/albums/s...ture222032.jpg

http://i563.photobucket.com/albums/s...ture222070.jpg

The front of these trucks cause a lot of issues when sitting them low and running taller tires. The hood makes up the top of the fender on these trucks and there is a thick flange where the hood meets the lower fender section. This flange leaves no room for tire clearance unless the tires are sucked way in. We decided to split the hood and make the fender more like any other vehicle where it goes all the way up to the top of the door. This will also get rid of a lot of the unnecessary gaps in the front end of this truck.

Started out by fabbing filler strips to eliminate the gaps and weld the fender to the hood as well as the cowl side to both the hood and fender.

http://i563.photobucket.com/albums/s...ture222045.jpg

http://i563.photobucket.com/albums/s...ture222048.jpg

The hood and fender were then cut along the filler strip and the material between was removed. The filler strip was then tacked into place making the fender, and hood one piece.
http://i563.photobucket.com/albums/s...ture222061.jpg

The side portion of the hood was then cut away from the center so that it could form the top of the fender.
http://i563.photobucket.com/albums/s...re222062-1.jpg

Still have to finish the cowl to fender and cowl to hood filler on Monday. For now the filler strip is held in place. The goal is to make this look like the truck came from the factory this way.
http://i563.photobucket.com/albums/s...ture222069.jpg

Outstanding work as always!