Builds Project Rosie Ruby the Poverty Princess

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Flare holes and antenna hole welded, dents pulled. Ready for filler.

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not to hijack this amazing thread, but after spending extensive time and $$ on my 80 to "refresh it" I'm really blown away at how hard and how expensive parts are getting for these things. I absolutely feel that we have crested the hill of going from fun truck to collector. The days of calling Beno or Cruiser Dan and ordering about anything is gone. I started tallying receipts and I had to sit down as the total continued to grow.
 
Do the inside of the doors get repainted or sealed in some way to prevent rust ?
Just curious.

And nice work !!
Where the welds are, yes. Epoxy primer and then seam sealer.
 
Where the welds are, yes. Epoxy primer and then seam sealer.
Professional all the way !
That was my concern where the weld are and the paint that it burns off in the immediate area.
 
Kelly, any chance you can share your process for welding the flare holes, and treating the seam around the door skin that tends to split and rust?

I'm tackling a similar job on my truck, on a much tighter budget....

Thank you
-Rob
 
Kelly, any chance you can share your process for welding the flare holes, and treating the seam around the door skin that tends to split and rust?

I'm tackling a similar job on my truck, on a much tighter budget....

Thank you
-Rob
Seam around the door skin? You probably mean just the lower section. If I see bubbling seam sealer on the lower doors, I remove a few inches of the lower door skin, clean up the rust and make a new skin section. It’s a bit tough on the 80, especially the rear doors because of the curvature in the back. Fronts aren’t too bad if you have a slip roller. Basically, if you see rust along the seam sealer, it’s grown much larger than you can see behind it. I replace every lower door skin on 60’s, 80’s aren’t as bad. The flare holes: I cut little pieces, hold with a magnet and weld them in, SLOWLY and keep the heat down. I use a 2” 36 grit roloc disc on a 1HP die grinder, and again, SLOWLY, at low speed keeping the heat minimal. Doors I just welded had ZREO WARP because I was patient. I’m having a batch of these flare hole patch pieces laser cut soon so I will just have them ready. PM me with other questions and I’m happy to answer what I can.
 
The parts list for this build includes new flares, though you are welding the flare holes closed. Is the truck going flareless, or will you use a different method to attach the flares?
@shellb decided to embrace the full poverty pack mentallity
 
Looking better everyday!! And getting closer to paint!
Can't wait to see it completed. Hoping to have this done in the nearish future. Wondering whether you are replacing any of these fender seals, as they are not in the parts list:

53736-60010 SEAL, FRONT FENDER APRON TO FRAME, NO.1 RH
53737-60010 SEAL, FRONT FENDER APRON TO FRAME, NO.1 LH
53738-60011 SEAL, FRONT FENDER APRON TO FRAME, NO.2 RH & LH
53735-60010 SEAL, FRONT FENDER APRON TO FRAME, NO.3 LH & RH?

I believe there is a seal or two for the rear left side also.
 

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