Bedside replacement

[kandyman]

I am in need of a tutorial on how to replace a spotwelded bedside.

[painthuffer]

Easiest way is to do this;
(this is making the assumption that you are installing an outer panel on a oobs,obs,nbs,nnbs pickup)
1.remove bed

2.I always remove the bulk of the bedside with an air chisel leaving the edges,and areas that are welded.This aides in accessing the backsides of welded areas and allowing you to work with smaller pieces of the bedside.(NOTE:Be careful of where you cut if you do this,some areas have overlapping panels underneath which you don't want to disturb.)

3.Use a spotweld drill,or 3 inch grinding wheel to remove the spotwelds.Being careful not to breach the panel directly underneath.

4.Once all the spotwelds are removed.Use either a hand chisel or air chisel,place in between the adjoining panels and seperate.If you encounter trouble getting the panels apart try redrilling the spotweld.(NOTE:Usually the spotweld will dimple in the area it is still bonded allowing you to clearly see where to drill.)

5.Once the existing panel has been removed completely use a flap wheel or 80 grit abrasive disk to clean the mounting areas and weld closed any holes made from drilling or grinding out the spotwelds.And grind smooth.

6.I recomend using weld thru primer on all the sufaces that will be welded on,for corrosion protection.

7.Prep the new bedside by drilling approx.5\16 holes about 3-4 inches apart.Try to use the same number of welds applied at the factory on each of the flanges.Once the holes are drilled grind the surrounding area and the backside to free it of any remaining burrs from drilling.This will ensure a tight fit.

8.Install the new panel(NOTE:It helps to start by the tailight area and go forward.)And clamp in place.

9.It's always best to throw the tailgate on at this point and check your gaps and fitment and make the necessary adjustments.There should be a paintline left on the front panel from where the old bedside was.This serves as a perfect line to line up the new bedside in the same location.

10.Time to weld.Nice,flat,plug welds,no holes.

11.Always best to use your trusty 80 grit wheel to smooth those welds out.Using the hrd stone type grinding wheel leaves gouges itn the metal.I like to use a 80 grit 3 inch wheel on a small air grinder,and then run over that with a 80 disc on a DA sander.If you have it available.After that lay down some etch primer,and get ready for paint.

Hope that helps.

[kandyman]

Thanks alot for the help.

[JPetrucci84]

Nice. Too bad I didn't find this earlier when I could've used it. Thanks, though!