Auto body repair & detailing: 01 Silverado Repair, chevy 1500 silverado, spot welds

Question

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Followup To

Question -
Recently, our 17 year old son learned about cutting turns too sharply in my 2001 Chevy 1500 Silverado pickup while my wife and I were visiting friends. I’ve received estimates of $2700 and $3100 for complete repair. Unfortunately, our insurance company still remembers our 20 year old’s accident from ’04 making me extremely reluctant to get their attention again. This leaves out-of-pocket or lowering the cost through sweat equity. (Yes, son #2 will pay for the parts and be actively involved in the work.)
I’m fine with wrestling with stubborn parts, in-depth mechanical projects, and minor body shaping, but don’t want to wander where my limited welding skills will become a liability. I’ve had my son research the parts and they should run under $800 ( I also have every intention of leaving painting to the pros.)
You can view the damage at these three links:

http://img435.imageshack.us/img435/2084/2001chevyrvgatedamage001vm3.jpg

http://img435.imageshack.us/img435/4160/2001chevyrvgatedamage002yu0.jpg

http://img456.imageshack.us/img456/3268/2001chevyrvgatedamage003ex7.jpg

  Apparently the fender comes as a unit with the inner bed which leads me to believe the assembly basically bolts in. True?
  Would you recommend Bondo or lead after pounding out the pillar-trim dent?
  Given my 30+ yrs. of successful driveway/backyard mechanical experience is this a doable father-son project or will I be opening a regrettable can of worms?

Thanks,
Geoff West
Glendale, AZ


Answer -
ouch, Actually the box side of a truck is not bolted on, it is spot welded over 25 times. The only way to remove is to drill the spot welds and use an air hammer and a split bit and then remove the box side( there a re a few bolts) and then weld a new one on, grind wels and then paint. Is is actually as pretty complicated repair and takes an average shop about 3-4 days to repairIf you can pop the dent out most of the way, then just Lightly bondo and sand then paint. The problem with that is it is a newer truck, and you don't really want bondo on it.. The cab corner can be pulled and then skim coated with bondo, it is a small enough area, bu the box side should be replaced. If you look at the inside edge of the bed, and around the inside of the wheelwell, you will see all of the spot weld that need to be drilled out. They make special spotweld drill bits for the exact application. Hope this helps.

Brandon,
Thanks for you fast response. Another poster has suggested using structural bonding adhesive as a way to get around my lack of welding expertise. (Though my son assures me he could handle the wire welding if I just buy one.) Obviously it is still a bunch of work, but that part doesn't bother me. Assuming we tear things apart carefully and are patient with placement, what do you think about the adhesive approach?

Thanks,
Geoff

Answer
You can definitly glue the panel on. The only disadvantage of glueing is obviously the mess and the you can not really move it around that much after is is put in place, you don't what the glue to be everywhere by sliding it around. If you choose to glue then make sure you buy the long set, not the fast set,  Make sure to use a very even coat of adhesive. Good lusk and send me pictures when it is done.