Continuing cab rust repair and clean up.
The bottom of the air handler rust out predicable as derby and
water collects in the air duct. Seen here is the cut away passenger side view. The thinned rusty metal is removed.
A patched fabricated out of new sheet steel with a hammer
and sandbag. The patch is ¾ of an inch bigger than the hole on the two overlapping
sides. I cut a drain into the bottom of the patch to help remove any future derby.
I will let you know is it works in another 35 years.
To hold the patches in place I predrilled some 1/8 inch holes
trough the over lapping parts and screwed them tight together.
I then drilled some ¼ inch holes in the outer layer
between the screws and plug welded in the patch. The screws were then removed and the 1/8th
inch screw holes welded shut.
The driver side.
This sides patch placed on the out side to show overlap and
predrilled screw holes.
Patch in place.
Screwed.
welded.
Ugly I know but that's what the fender will hide.
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