BBW Conversion

[Joemomma1]

I am going to start a thread on how to do the above mentioned w/ step by step pictures. I am currently debating what will be the easiest way to do this. I have discussed this with a few people who have already done a conversion and have a general idea on what needs to be done. It was a real pain in the @$$ getting all the spot weld drilled out of the donor panel and do not want to do it again on getting the small window panel out. I have came up with cutting both panels in the same locations and welding it in.

I want to cut 1" or 1.5" below the seam the screwdriver is pointing at. This is the driver side.

Passenger, again 1" or 1.5".


I want to do the same thing all the way around, get the idea?



To me it just seems easier doing it this way rather then drilling the welds and gring them smooth and risk damaging the outer skin. Please comment with any ides, concerns or comments. I want to make a thread as a reference for anyone who wants to do this since there isnt one made yet.

[shrunken66stroker]

I've thought about doing this myself. I'm planning on leaving mine small at the moment but I'll definitely be watching this thread.

[aerotruk63]

I removed the inner panel without damaging the outer panel by slipping a hook knife between the seams and tapping the hook knife with a hammer. It sheared the spot welds nicely. There is a thread on Stovebolt explaining the process of the changeover by another member.

[jonzcustomshop]

I would do the 1-1.5 along the seam if you plan on retaning the seam, on the edges by the door frames I would definately do the spots, and along the bottom as well.
it would be easier and create way less heat all around just spotting it back in as opposed to running 4 + feet of weld bead...
what I would do is go ahead and cut the whole thing out where you mentioned, and the find all the spots, and run over the top of them with a grinder or cut off wheel, you can slowly thin the metal around the spot, and then wiggle the pieces of metal off. you also don't run the risk of going all the way through like when you use a drill.

[502tripower]

I would drill the spot welds. If you have a good cutter it goes fast. The end result is your panel will fit perfect. I make my own spot weld cutters out of old drill bits by grinding to the shape of a forstner bit. I have done many of these conversions. I think you will create a big headache if you try it like you say. Not to mention ruining the BBW inner liner. There is very little grinding if any after I plug weld the new panel back in.

[Hilandr451]

I've done a BBW conversion on my '66 replacement cab.
(Hilander's BBW conversion, '64-'66 Chevy)

I used the "cheap-o deluxe" spot weld cutter and I had fairly good results.




I chose to weld up the seam where the roof panel meets the cab back. What a ***** those inside corner seams were to fill!!!



If I were to do this again, I would do what Joe's doing and butt-weld the "new" panel to the old.

Very important!!!
Make sure you measure very carefully and center the inner panel opening with the outer panel press-out before you tack the new panel in place!!! You'll only have about 1/4" of gasket flange on either side of the BBW opening to install the glass!!! That means if you're off side-to-side by a mere 1/8" you'll have 3/8" on one side but only 1/8" on the other!!!


Before


After

[aerotruk63]

If you apply a panel adhesive for tractor trailers to the arch in the roof line and spot welded the door posts and lower back of the cab, do you think the panel adhesive would let go? I've heard the proper way to do the installation is to remove the roof panel. If you could adhere the two non structural panels together you could avoid removing the roof panel.

[502tripower]

Originally Posted by aerotruk63

If you apply a panel adhesive for tractor trailers to the arch in the roof line and spot welded the door posts and lower back of the cab, do you think the panel adhesive would let go? I've heard the proper way to do the installation is to remove the roof panel. If you could adhere the two non structural panels together you could avoid removing the roof panel.

It is not necessary to remove the roof panel. Just the back window liner is all that needs to be removed. I have not done it myself but, have friends that have used just the new panel adhesive used for new car construction to install the BBW liner and, it worked perfect. In both cases the trucks were already painted and they did not want to go through the repaint process. When they were done you could not tell and, in one case the truck was T-boned in a intersection and the panel was warped bad but the adhesive held with now separations.

[Joemomma1]

Originally Posted by 502tripower

I would drill the spot welds. If you have a good cutter it goes fast. The end result is your panel will fit perfect. I make my own spot weld cutters out of old drill bits by grinding to the shape of a forstner bit. I have done many of these conversions. I think you will create a big headache if you try it like you say. Not to mention ruining the BBW inner liner. There is very little grinding if any after I plug weld the new panel back in.

I have not seen those bits around here. I used the same type that Hilander used. I did not care for them at all, really soft metal. I will drill out the welds but have to find those bits first. Eastwood?

[502tripower]

Originally Posted by Joemomma1

I have not seen those bits around here. I used the same type that Hilander used. I did not care for them at all, really soft metal. I will drill out the welds but have to find those bits first. Eastwood?

I do not know if anyone offers those bits as spot weld cutters anymore. I grind my own from old drill bits. Can you grind your own from old bits? Yep It does look like Eastwood does have them. You can see how easy it is to grind you own looking at their picture. Bottom of the page. http://www.eastwood.com/email/defaul...ot_weld_cutter

[Joemomma1]

Originally Posted by 502tripower

I do not know if anyone offers those bits as spot weld cutters anymore. I grind my own from old drill bits. Can you grind your own from old bits? Yep It does look like Eastwood does have them. You can see how easy it is to grind you own looking at their picture. Bottom of the page. http://www.eastwood.com/email/defaul...ot_weld_cutter

I have an idea on how I would but dont have a dremel or anything small enough to make it look like that. Im going to check out a few more spots in town. If not I may have to order it.

[502tripower]

Originally Posted by Joemomma1

I have an idea on how I would but dont have a dremel or anything small enough to make it look like that. Im going to check out a few more spots in town. If not I may have to order it.

I grind all mine on 8" bench grinder. Takes less than a couple minutes.

[McCoyAZ]

DO any of you guys have a DETAILED tutorial showing how to remove the BBW panel from an old donor cab?

I have been cutting and sawing trying to seperate the welds to get the inside panel out and am not having very good luck here.

Pictures and detail explanations work best for me.

And I thank you in advance.

[Novalicious]

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