I have done a little body work from time to time and a fair amount
of structural steel welding, but had never really done any body
sheetmetal welding or any major body surgery such as this. As it
turned out, the project was not too difficult and I have been
pleased with the results. Time and patience, I think, are the
keys to getting it to come out well.
I started by placing a drafting t-square on the side of the bed and
marking a line perpendicular to the top bed rail where I wanted to
make my first cut (the rear one). I then measured and marked the
opposite side of the bed in the same place. Before starting my cuts
I removed the inner bed panels.
I used a jigsaw with a fine tooth bi-metal blade to make the cuts,
cutting the sides first and then the bottom of the bed. The frame
and rear-most body mount help to keep the rear portion of the bed
in place while the cuts are made. With the jigsaw cuts complete,
I then had to do a little cutting where the sides meet the bottom
of the bed using a die grinder with a cut-off disc.
Once the rear tailgate and tail light section was removed, I measured
forward 14 inches and made the forward cut marks. I made these cuts
in the same manner as the first ones and removed the extra 14 inches
of bed.
I had originally planned to use a flanging tool to flange on of
the mating edges so the two edges would overlap when I put them
back together. However, I found that my two cut lines matched so
closely that I decided to simply butt them back together and weld
them.
I brought the tail piece back up to the bed and began clamping it
in place using c-clamps at the top rail. Once it was secured, I tack
welded each side, moving from top to bottom. I then tack welded the
bed bottom as well. Working slowly and using small 1 inch weld beads
I reassembled the two halves by completely welding them together,
while spacing the weld beads and progressively filling the entire
seam. On the side panels I used small sheetmetal backing strips
(made from the left over bed panels) hidden inside the double
wall panels for added strength. This also made welding the sides
much easier.
I also cut down the side panels so they could be reinstalled in the
bed. With the welding complete, I used a small amount of body filler
to completely smooth over the weld area, and then primed and sanded
the area to prep for paint. I trimmed more sheetmetal from the area
behind the fenders, and modified my rear bumper to add some side
nerf protection in this area. With the trimmed bed my departure
angle is now about 55 degrees.
ABOVE: Richard Charles bobbed 14"
out of the bed of his '88 truck.
LEFT: Jason Maxson bobbed his bed and
put an Xtra Cab cab on a standard bed
frame. Very cool!
Check out Brandon Miller's '83 truck
bobbed bed.
Check out C. Andrew Zook's '92
bobbed bed.
Check out Steven Brown's
Tankota SHORT Short Bed.