Started my big back window conversion today

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Well it has been below freezing down here for most of the past 2 months, today it warmed up to about 60, so I rolled the Truck out and started cutting on the cab. I may have taken a bit of a different approach than others, but I wanted the big stuff out of the way so I can get to both sides around the spot welds as much as possible.

I started inside and took a 4 inch grinder with a Cut off wheel and sliced up the sides then ascross the top and bottom. I moved outside and rough cut around where the big glass will be. Then I just removed the big chunk of metal and I had a big hole in the back of the cab.

I can work on it by drilling out some welds in my single car garage without making to much noise since the grinder part is done. Everything echos like crazy in the small garage. Plus I can do this while the weather is back below freezing starting tomorrow.

It isn't finished but I love the look already! It lets in more light inside the cab, and has the look only a big window can show off.... A classy look!

I I'll have to post pics one at a time from my iPhone

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Pic1

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Pic 2

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[chad64chevy]

looking good, I did almost the same but cut closer to the door jam! a lil bad news is your grinding is over yet, you still got to do some grinding on the window lip, where the gasket sets on! remember like I told you on the phone to check and double check the top lip inside the cab, you want to get that really close together, I didn't get it real close in the corners and is why I filled that seam in on mine! do a lot of dry fitting of the inner panel, and make sure you have ALOT of clamps to hold it in place for the panel adhesive and the welding! good luck and keep posting you progress

[sigshooter]

Here is my donor inner panel

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Originally Posted by chad64chevy

looking good, I did almost the same but cut closer to the door jam! a lil bad news is your grinding is over yet, you still got to do some grinding on the window lip, where the gasket sets on! remember like I told you on the phone to check and double check the top lip inside the cab, you want to get that really close together, I didn't get it real close in the corners and is why I filled that seam in on mine! do a lot of dry fitting of the inner panel, and make sure you have ALOT of clamps to hold it in place for the panel adhesive and the welding! good luck and keep posting you progress

On the grinding.... My plan is to leave the outside rough cut until I get the inner panel in place, this will give me plenty to weld to around the window opening and once the inner panel is in place I can cut or grind down to the inner panel lip.

I have a big window cab here and two more big window back halves to measure by, but I am close right now just trimming once it is all in place.

I will probably be talking to you again about it before I start welding, but at least this much is done..... And I am loving the new look!

[ol_skool_chevy]

I got my eye on this project................

[chad64chevy]

yes, i'll agree I love the look after I did mine! I wish I would've had a couple cabs to measure by would of had my glass in a lot sooner!! in a couple weeks I might be able to help you out, will talk soon!!

[sigshooter]

Couldn't wait to get in there and get the rest of the inner panel out! I got both sides and the bottom drilled out, now I just have to get the top apart.

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Stopped by lowes and picked up a couple hook knives to work on the top with.... I will post pics of how it goes

[kieth]

Looking good, least invasive way to install a big back window I have seen. Seems like all the others had a lot more cutting on the exterior of the cab. Your method looks lots cleaner and a whole lot less work (if that is possible) Kieth

ps let me know when I can come down to the Muskogee shop and I will bring you the freeby radio........Kieth

[clemdaddy]

nice work sig... good to see you're staying on it. this winter has been brutal over here, i haven't gotten a thing done. i guess old fingers just don't jive with cold temps. but springs a coming... maybe.

[Barney 66]

Kudos on having the Balls to start this! I am keeping an eye on this project! Might be a later addition to my (P.I.O.M.T) "Put it On My Tab" project lol

[sigshooter]

Thanks , it was a bit scary at first but once I did the first slice with the grinder..... Well there was no turning back at that point.

I got a lot of information off here and felt confident I could do it!

[sigshooter]

I removed what was left of the piece at the top (headliner) tonight. I bought 2 hook knives at lowes. One kobalt with a plastic handle and one Irwin with a wooden handle. The plastic/rubber handled kobalt looked very sturdy, but it broke the first time I tried to cut thru a weld. The wooden Irwin worked thru the entire job.

What worked best was to strike it a couple times then work the 2 pieces back and forth and it would snap into. This seemed to put less stress on the headliner and not distort it from beating on it with a hammer.

I will post pic soon

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Pic 1

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Pic 2

[ol_skool_chevy]

what happen?....did this project die??

[sigshooter]

No , my mom is battling cancer so I haven't had free time to finish it

Hopefully in the next couple weeks