More recent work on the Crew cab...
I repaired the panel above the gearbox that was rotten where both engine side trays meet it. Did the same repair both sides:
Then, the repair panel we made was welded in and clamped in place while we trial fitted the other new panels:
The new top hats and side supports were clamped in place to check everything was good before any welding:
The side panels and rear corners fitted quite nice. The rear engine lid hinge panel needed a bit of work, and the sides supports still need lengthening at this point, but now we were happy with the top hats etc they were welded in place. The engine lid hinge panel was twisted, with the corners and engine lid fitted the gaps were awful. After some work they are a little better but still need more work:
We trial fitted the gates at this point to see where the captive nuts needed fitting into the side panels of the bed framework, and to check the mounting area on the BBT engine lid hinge panel and rear corners. None of them lined up

But they will be OK with a bit of work... Looks a bit like a finished bus:
I spot welded both side panels to the smaller side panel at the back of the cab that meets the bulkhead:
The lower hinge section of the post was repaired with a Klassic Fab panel. I cant find pictures of this but once this was repaired the side panels were trimmed down, fitted and pinned in place once fitting nice, ready for welding:
The rear bulkhead and bed were trial fitted now the new side panels were in place, and sides and quarters mocked up on the repaired framework:
The original cargo door was twisted / damaged. We have an good original paint door that we used to check the gaps... Pretty pleased with this:
There was so much work in all the above. Working with a mixture of panels from Klassic Fab, Autocraft, and the new BBT panels in weld through primer... All pretty good but all need work. The rear corners are not great. The holes for the gate hinges are in the wrong place, and the shape isnt perfect, but they are good enough overall. Just to show how much modification these panels need - here is the original battery tray, with the new Autocraft panel on top of it. Completely different shape where it meets the corner... And, neither of those panels fit the new corner. No big deal, we will just reshape the new panel when its fitted to fit the new corner:
A little repair I forgot to mention - The radio holes were slightly damaged, so they were repaired and are now have the correct size hole. Before:

After:

And the other side:
RHS inner B post panel tacked in place, and side panel pinned in place:
New bulkhead trial fit with new B post:
Side panels and corners lined up and pinned in place:
As far as I know no one makes rear tubs for a truck so we modified a pair of tubs from Autocraft to clear the vents as the originals. We mocked them up with the side panel, marked where they needed to be re shaped, cut them then got them in the stretcher and worked the edge until they were fairly straight:
The shape along the lower curve at the end of the sill wasnt the same profile as the rear side panel:
If we would have left the tubs like this, the side panel would have been a mess after welding them together so we reshaped them. The rear closing panel had a nice curve that matched the side panel, so that was used as a template:
You can see the difference with the template over the tub:
After a bit of reshaping just using a hammer and dolly:
Much better fit with the side panel:
The side panel and tub were fitted and pinned together, then removed to finish welding the tubs:
We welded the top cuts in the tubs and spot welded the new side supports:
We spent ages getting the door gaps nice and making sure the body was in the right position over the chassis forwards/backwards and left/right. Once happy we pinned everything into place:
Thats where we are at the moment.
Cheers