My 78's rear quarter/sill repair

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On all the late model trucks I've restored that I've replaced the rear floor in (almost all of em), even with rust similar to yours, I was able to transfer the fuel tank and heat shield brackets to the new floor. You can drill em loose with a spot weld cutter. Take careful measurements, and of course pay very close attention to left, right, front, and back before welding. You won't find a floor with all the brackets. Even the gas tank brackets can be duplicated if necessary with a little practice.
 
First patches...

Bought some steel ...

First patches coming along ... all my "brake" work done on a bench vise at this point.

Weld training in-process ...:grinpimp:

Going to check out the Pacol guy that has recently been posting (on mud) about body parts for a sill replacement.
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Anyone Have a Source for Sill Cover?

Great thread for a newcommer to sill fabrication! can't find the ebay seller , and need a source for a late model sill cover. Anyone know of one (or better yet - have one)?
 
Gusb, great thread! How's that Millermatic 140 working out for you? I'm in the final week of a welding course that I'm taking through the local community college, and am planning on buying the same welder. BTW, you can make your own sheet metal brake now that you can weld. Miller - Projects - Bending Brake looks like a good first welding project.
 
Gusb, great thread! How's that Millermatic 140 working out for you? I'm in the final week of a welding course that I'm taking through the local community college, and am planning on buying the same welder. BTW, you can make your own sheet metal brake now that you can weld. Miller - Projects - Bending Brake looks like a good first welding project.

Martian - ended up buying the MM 180 instead of the 140 - and it's been great. Had to run a new 50 amp breaker box/wiring etc. in the garage, but I think it was worth it. In the end I just decided it would be a little better overall and handle some heavier stuff in future. Thanks for he project link - I could really use a Brake.
 
Great read!
Im in the process of doing what it is that youre doing right now.
I ended up building my own sill, and tail gate pillars out of steel.
2x2 square for the sill, and 2x1 for the pillars. I also had to make my own fender wells for both sides.
Texx is right...removing those fender wells is a ROYAL PAIN IN THE ASS!!!!!!!!!!!!!!!!!!

Here's a couple of pics of my junk...
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More or less finished my rebuild of the "stock" sill...
see:
Updated:
https://forum.ih8mud.com/40-55-series-tech/235482-bumps-my-78-s-rear-tub-fenders-3.html#post4742310
Great read!
Im in the process of doing what it is that youre doing right now.
I ended up building my own sill, and tail gate pillars out of steel.
2x2 square for the sill, and 2x1 for the pillars. I also had to make my own fender wells for both sides.
Texx is right...removing those fender wells is a ROYAL PAIN IN THE ASS!!!!!!!!!!!!!!!!!!

Here's a couple of pics of my junk...
 
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