How hard is it to replace cab corners on an extended cab? Can it be done easily at home, what type of welder would it use?

 

Welder wise use a litte lincoln wire feed welder. If you are new to welding make lots of practice on similar guage dheet metal make sure you know what your doing and look inside the door panel it will say what settings to have depending on the size of metal your working with.

 

Depending on how much rust you will have to cut out, it can either be a simple batch to a large lower chunk of the cab, it also helps to have the bed removed to do it properly.

Use a Mig welder, preferably gas so you wont have to chip away the large chunks of slag.

 

Cut out the rusted areas with a cutoff wheel the same size or smaller then the patch panel and trim the panel to fit. Tack in with a wire feed welder spacing your tacks apart and coming back to fill in to keep the heat down.

Once you have welded all the way around the panel, knock down the bulk of it with a grinder, then come back with the grinder and a flap wheel to smooth it out before adding a thin coat of mud on the seam. It is much easier to do a proper job when you remove the box first.