Figured I was overdue for an update.
The next task was filling in the lower corner and the top of the windshield frame. To get the radii right, I put cardboard behind the opposite corner and used spraypaint to transfer the profile. I cut the piece out and cut it to fit the missing space at the bottom of the window frame. When the piece fit, we cut the same shape out of 12 gauge sheet metal and welded in. Still a bit new to this, but it didn't turn out half bad:
I then laid out the top frame. I laid this out directly from the new windshield to ensure a correct fit. I added a marker's width under the assumption that extra metal can be ground off, but welding new metal on is much harder.
Bobby cut it out, we fit it up, and he welded it in. Some grinding, sanding, and a coat of primer later and...
..we might actually have a cab!
Our surface prep process is as follows:
Clean/degrease with acetone, as needed (most of the machine is grease and oil free).
Sand with 80 grit paper to expose non-faded paint (its under there.....) and/or remove loose rust.
Wipe down with acetone to expose a perfectly clean layer of paint or metal.
Prime. Right now we're applying Rustoleum Heavy Duty Primer with brushes/rollers due to limited areas and lack of a paint booth. It is pretty thick, but it works well in the areas of heavy pitting we are encountering in all the tight spots around the cab. It shows brush marks, but we figure they can be sanded out for the final paint job. For now, it gives us a rugged finish that will last until spring when we can spray a proper finish.
More to come...
