The Welding has begun!

Hello Gray Ghost Fans!

Boy, time sure has flown!  It's now 2022 and work has been going on all throughout the fall and winter.  Time to get you all caught up.  I'm going to try something different this time: very few words and lot's of pictures.  I've been snapping shots all along the way, so there's lots to see, but writing for each pic may be a little too much.  So we'll just go with the pics.  Enjoy!

Where we started with the cab:

Passenger side floor pan.

Passenger side lower hinge pillar and hinge.

Passenger side upper hinge pillar and hinge.

Lack of clearance between floor pan and frame rail.

Large hole where rest of inner cowl should be.

Rot cut out of floor pan.

Looking down on outer cowl where the fender is bolted on.

Side view of outer cowl and missing inner cowl.

Head on view of outer cowl assembly.

Driver side lower hinge/bolt disaster.

Passenger side lower lock pillar close up.

Looking down on passenger side inner cab corner (or what's left of it).

Passenger side lower lock pillar.

Passenger side floor pan left of battery cut out.

Looking down at battery cut out and floor pan.

Passenger side floor pan/inner cowl.

Driver side floor pan/inner cowl.

E-brake cut out/inner cowl.

Head on view of driver side inner-to-outer cowl.

Driver side outer cowl (with inner cowl in background).

E-brake pedal (extended through firewall) and mount.

Driver side inner-to-outer cowl rot.

Driver side filler panel rot.

E-brake mount.

The work begins:

Original rocker panel with lower hinge pillar still attached.

Rocker panel removed, lots of spot welds drilled out.

Replacement rocker panel initial test fit.

Original passenger side rear shackle (and shims) front view.

Original passenger side rear cab shackle (rear view).

Filler panel from between cab and bed.

Original rear shackle, ready for disassembly.

Original rear shackle parts.

Original rear shackle parts.

Rear cab shackle original bolts and replacement.

Original passenger side front cab mount.

Restored shackle parts, ready for assembly.

Restored rear cab shackle (passenger side).

Restored rear cab shackle in place.

Original floor pan showing cut lines.

Original and replacement under floor braces.

Top view of original floor and frame.

Top view of under floor brace and cab mount.

Initial fitting of cab mount (silver disk on side of pic).

Fitting the floor pan, held in place with clamp.

Looking across floor pan. Cab mount is in place.

Floor pan view from passenger seat.

Looking down at floor pan and sheet metal screws. Each screw has to be removed, one at a time, and the hole welded shut.

Floor pan held in place with sheet metal screws.

Looking down at inner cowl gap.

First look at both inner and outer cowls, roughly where they'll go.

Inner cowl against floor pan flange, viewed from outside of truck.

Inner cowl modification, space to be filled to make it fit properly.

Top view of inner cowl modification.

Inner cowl modification tack welded in place.

Inner cowl replacement test fit.

Passenger side lower hinge reinforcement.

Lower weld nut, or what's left of it, prior to removal.

Hinge parts before blasting.

Lubrication hole...I think.

Using a bolt, washers and nut to hold welded spacer in place for reattachment.

Welded washer back in place.

Restored hinge parts.

Restored hinge.

Restored hinge.

First real weld...ever!

Weld penetration of first real weld.

New rocker panel tack welded in place. White lines are alignment lines for trim mounting holes which do not get welded shut.

New rocker panel ready for primer.

New rocker panel welded and primed.

Back side of rocker panel showing weld penetration.

Weld through primer on new floor pan.

Weld through primer in place, epoxy is next.

Weld through primer applied in places where new floor pan will be welded to original floor pan, gray is epoxy.

Clamps and sheet metal screws hold floor pan in place while epoxy dries.

Rear view of replacement floor pan/original firewall.

Initial test fit of replacement inner cowl.

Welding of floor pan in progress.

View across new floor pan towards inner cowl remnants.

What's left of the inner cowl.

Floor pan welding complete/ primer and paint applied.

Restored hinge test fit rear view.

Restored hinge test fit.

What's left of original weld nuts that lower hinge bolted to.

Hinge reinforcement with doubler and new weld nuts.

Mock up of lower hinge pillar and inner cowl.

Front view of lower hinge pillar with initial welds in place.

Hinge pillar bottom with initial welds in place.

Close up showing low spots on welds that need addressing.

Momentary switch for fuel pump and heater switch on refurbished mount from 1940's Ford car.

The old man, enjoying retired life.

And there you have it, June 2021 through January 2022 in pictures.  It's been a lot more work than it might appear. So far, I'm pleased with the outcome.  However, the proof will definitely be in the pudding when I rehang the door!  Assuming that none of the welds pop when having to hold that heavy door, the big question will be: does the door still fit?!?  I've tried as hard as I can to not disturb the hinge pillar orientation.  I'm assuming that it was still good when I got the truck!  If it was and I didn't bollux up anything, then the door should still fit properly.  Only time will tell....

That's all for now.  I'll try to make more regular posts, as things are really starting to progress!  As the old police officer used to say before dismissing the other officers: "let's be careful out there."