Posted by Russ/Wyo on Monday, September 25, 2006 at 9:30AM :
In Reply to: OT bodywork advice posted by apb in NY on Sunday, September 24, 2006 at 7:39PM :
Just swap out the entire cab. I did that about 10 years ago using an '87 Dodge D150 2X4 cab onto a '91 Dodge CTD 4X4 frame and running gear. You'll have to replace all the wiring harnesses inside the dash and replace the short 2X4 transmission hump with the taller 4X4 hump. I used a jig saw with a metal blade to cut out the transmission humps, but I cut the 4X4 hump 1-inch larger all around than the 2X4 hump. I used seam sealing putty between the overlapped edges and pop riveted the 4X4 hump into the 2X4 cab bottom. No leaks and you'll never know the difference unless you are underneath the truck and looking close. The entire hump transplant took one day. The cab swap took longer, and luckily my daughter helped get the wiring harness back inside the dash with her small hands.
E-mail me if you want a few more details.