I chose to replace the rear section of the body with an aluminum replacement tub from Aqualu Industries. I read most everyone's pros and cons on using an aluminum replacement tub. I based my decision on the following:
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My existing tub was in such poor condition that it would have required some fabrication in addition to purchasing the readily available parts from some of the LC vendors. |
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Time - buying parts, buying a welder, learning how to weld, practicing, cutting out old panels, welding in new panels, etc. This would have significantly stretched out the timeline of my project. |
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The probability of making a big mistake seems high with weld-in panels, particularly with the extent of the repairs my tub would require. I've also heard mixed reviews on the quality of the panels from the major vendors. |
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Aluminum tub opponents will lead you to believe that your whole truck will quickly rot away due to electrolysis between the dissimilar metals. While electrolysis is a very real thing, I feel with proper planning and preparation, it can be avoided just fine. Many new vehicles are using a combination of aluminum and steel body components. |
In the shots below I have test fit the tub to the chassis, then attached the cowl. I test fit the hard top and doors and marked the locations for the door hinges, latches, hard top bolts, etc. Then everything was removed to prepare for body work on the individual pieces.
The cowl and windshield frame were sent out for acid dip and e-coat primer. With all the hidden recesses and lap joints on these two parts, I felt this was the best approach to completely remove rust and get a good coating of primer.
In the spring of 2004, I decide to fit everything up again in preparation for final body work. This proved to be critical as some slotting of the fender mounting holes was necessary, and some other minor fit adjustments were needed.
After purchasing some of the aftermarket fenders, I decided to use Toyota fenders. They are made from a much heavier gauge steel. I also purchased a set of OEM running boards. The diamond plate running boards sold with the tub just didn't look right.
I have begun working with a body hammer and dolly to pop out a few misc. dents that had accumulated through the years. The black spray painted area on the hood has had a dent beaten out. This is pretty fun once you get the hang of it.
In the fall of 2004, I finally got started on welding in new lower ambulance door skins. I had never welded anything before, and my skills showed through. The pics below show the doors cut and prepped (sandblasted the bottoms and sprayed with weld-through primer), and the new skins tacked in place. More pictures of the final product to come.
