1969 Chevy C10

I have heard of people cutting out the impossible to get places , straightening them , then welding them back in.
lol, yeah, that's why I have a 4"x 14" hole in the back side of said tailgate. only it's on the bottom and not on top where I need it.
 
Thanks, I was looking for ideas other then the stud welder, and the shape kind of reminded me of the smaller dents on the top edge of my tailgate that I tried my HF stud welder on and it won't move them, the studs just pull off after one or two taps. I'm thinking the welder is now junk but I refuse to buy a second one. (it did work ok for the most part). I'm guessing the tight radius and heavy gauge metal has the dent locked right in. Good thing I got all winter to figure it out. ;)
HF being the key indicator as to what went wrong. I learned that by experience over a decade ago and haven't found any reason to get burned again.

The trick to using a stud welder for smaller dents is in the slide puller. You have to exert slight pressure by pulling and then lightly tap the slide hammer against the handle. It doesn't take a lot to move the metal. You also need to evaluate the dent and the best means to pull it. Very similar to working the metal with hammer and dolly, you don't just go for the deep end and start hammering away.

Notice the picture below. The areas where the metal is dented and buckled do not have studs on them. The idea is to relieve the stress around the dent so it takes less effort to remove it.
Pulling Dents on Bed Right.JPG


Bed Right Side progress.JPG

Bed Right Side Wheel arch repair.JPG


The truth is, I am still a hack compared to guys who know how to work metal. You should see Chevman's '57 Nomad!!!
 
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Block sanding the poly primer. :(
Applied guide coat and then block sanded with 150 grit on a 12" sanding block for the straight sections and round Durablock for the curves.

Blocking Poly Primer on left quarter.JPG


For the most part it went well, you can see black epoxy primer showing in some spots and a couple of very small areas where metal starting to show.
Blocking Poly Primer on left quarter 1.JPG


Cleaned it up and shot 3 coats of 2k build primer. Apparently I hosed it on pretty good cause I got runs in it (a first for me with primer).
My old EVO4018 primer gun with a 1.8 tip gave up the ghost, so I bought an AirGunza with a 2.0 tip. I am still not used to spraying with it yet will be my excuse. LOL
 
I guess I was thinking about holes for optional equipment that was probably punched on the assembly line. RW punch shears it off, but I don't know what they used for these holes I've seen. Some holes just have a small flange on the inside, and some are nasty looking.
 
Reverse lights are not working so another issue to run down.
If I remember right, that's a 4 speed with a granny low, NP265, I think. If so, the switch is on the side of the trans, close to the bellhousing, and the wiring harness plugs straight into it.
 
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