41. Start welding the bottom area using about ¾ inch long stitch-welds
work around the corner, then let it cool. Heat buildup is the worst problem here.
42. A, B, &C After all of the jamb area has been plug-welded, hammer
that extra lip area around the jamb. Start at the bottom and work it part way
as you move to the top. When finished, it should be totally hammered around
tightly to the jamb. It also must be nice and smooth. After finishing, give
it a light coat of seam sealer and paint it to match the body color.
43. Weld approximately a ¾ inch section, them move over about 2 inches
and repeat. Heat buildup is a bit concern which may cause the area to warp, and
you sure don't want that across that bit back panel.
44. When welding areas like this, keep an air hose handy or a wet rag to
cool the area as you proceed.
45. A & B After working across the panel, start over with another set
of short stitches until the whole length has been completely welded. Remember
that this area is very susceptible to warping. Take every precaution not to
let that happen.
46. A, B, & C Now that the welding is finished and it has had time to
cool, start the grinding. A stone wheel can be used to take down the build of
the weld, then follow up with a large disc sander. We cannot stress enough
about the danger of heat buildup. The grinding process can also cause heat
buildup, so the same cooling procedures should be used here.
47. A light coat of body filler should be applied, and after it sets up,
the area can be ground down.
48. Your project is nearly finished. Put on a coat of primer and it's
ready for the seam sealer.
49. A & B Place masking tape along each side of the seam and fill the
crack with two-part epoxy sealer. As soon as it has been applied, wipe excess
off the seam so there is just a slight recess to the seam so it looks the same
as it was done originally by Ford.
50. After the area has been primered and sanded, the cab needs only a
touch-up of body color and your big back window conversion is finished.
51. It's a major facelift for sure, and anyone who sees it will have to
admit that it turned out great. It's hard to believe that this is the same
truck that we started with. Now that the back portion of the cab has been
spotted in, no one would ever know that Kirk's truck wasn't a fish-bowl model
from day one.
52. The skillful work done on the doorjamb area show no signs that it has
been reworked.
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To check out more Pictures of this Conversion, taken by Kirk Bates, Click Here
***All Images/Articles were used with Permission From Truckin***
