Well looky what we have here!!! A few wiggles and it came right out! I couldnt believe it. Should be simple to get the new piece in, in one piece. Ive been in this position before but this is the least stressful/least work it has ever taken to get here. Fingers crossed.
One negative is I noticed a broken weld. Its at the passenger side junction of the vertical wall and cabover area. It seems to be old though, no fresh clean aluminum to be seen. It moves quite a bit when you push on the wall. I cant decide if I need to get it repaired by a mobile welder(which is really hard to find around here for welding aluminum) or I should try to fab up some kind of mechanical solution or if bolting everything back together will be sufficient.
Good weld on driver side
Broken weld on passenger side
I painstakingly removed every staple and the remaining bits of carpet from the front wall so I could trace the shape of the opening onto my new panel. The original opening was not symmetrical because of the location of the fridge behind the drivers seat. When I was taking my measurements I decided I was going to open up the cut a little to give myself a little bit more leg room. Should gain about an inch which will be nice. Im 6 feet tall and the seat is just a little too close to be comfortable on long rides so this will be a welcome change.
I managed to get both the front wall and cabover bed panel traced onto the new plywood while grilling dinner tonight. When I bought the plywood a month ago I had a guy at Home Depot cut it to the height and width I had measured and to my amazement it was within 1/16" of the original dims on both panels. Man would it be nice to have one of those crazy upright saws.
My work week is a little light so Im hoping to make a ton of progress. I picked up a gallon of Kilz Mold and Mildew primer but Im not sure what Im going to use for a finish coat. Ive read a thousand different opinions about what to paint it with but there doesn't seem to be a definitive answer. I need to figure something out in the next 48 hours, suggestions are welcome.
Also picked up my remaining parts from the powder coater. Got a few places to grind off the coating but it all turned out great. I really want to crank on this thing this weekend since the weather is finally dry for a change but the wife wants to go camping since we havent been in 2 months. Cant really complain either way.