Replacing Cab Corners

O

Outlaw

Once cab corners have been removed (truck) and inside area patched, repaired, or installed new inner cab corner replacement panel, its time to put on the outer cab corner. Everything is sand blasted and ready to install the exterior corner. I use a thin coat of U-Pol Weld thru Primer. But once the corner is welded on, there is a lot of bare sandblasted metal left behind with no protection. I can try and spray some epxoy in any areas I can get to, but coverage is not going to be 100 %. I can come back over the epoxy with bed liner or wax spray using an 360 nozzel on a bedliner gun, but that may still leave some area not protected.

Is there an easy way to protect the metal that is closed when cab corners are welded together? Im working on 56 Ford F-100 front cab corners. I have been putting it off for a long time just to come up with a way to protect them once they are welded closed. One thing that really helped was cutting out the inspection plates on the lower front side of the cab corners. Originally I was going to leave them closed. Then I realized this "window" into the interior of the cab corner could be used to get some protection in there. It will be much better than eliminating the inspection holes and losing the opportunity to come back after the welding and spray some epoxy and/or bed liner in there.

Also, all the time I am fitting and welding cab corners, that fresh sandblasted metel is sitting there unprotected. Im in a heated shop but I anticipate some flash rust will form before I complete the corners. What do you guys do?

One thing I thought of was using weld thru primer in the entire area that is going to be closed up. Wondering if that is like an acid etch primer and any epoxy applied later will not stick to it. Again, once the weld thru is sprayed, it will be several days before the outside corner is installed.
 
We epoxy everything before welding, then remove only a bare minimum of the epoxy to do the welding. Try to only remove coatings that fall in the HAZ. Those areas where other primers are certain to burn away and are not accessible can be coated with weld thru primer, though some here think it is no help.
 
Crash, what do you mean when you say remove only coatings that fall in the HAZ?
 
When you weld bare metal it changes the color of the metal near the weld, that's the haz. Heat affected zone.
 
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