I feel like I’ve done a good day’s work when I get home and the wife says, “You smell like metal.”

I was bemoaning the fact that I couldn’t work on our project last weekend by browsing through Instagram and checking out everyone’s cool rides.  I found that super clean, shaved C10 over there.  Matt and I had been talking about shaving the drip rails and sent him that pic asking what he thought.  I show up a few days later and half the drip rails are gone. Guess we agreed…

Cutting and welding around the doors was relatively easy, especially for me, since Matt did all the work. But over the windshield was tricky. As I learned, the drip rails is really two and sometimes three or four pieces of metal sandwiched together then pinch welded by the factory. When you cut that away, you’re losing the connection between the roof and lower supporting structures like A pillars, B pillars, roof supports, headers, etc…

Slick Truck with Shaved Drip Rails

Also, in the case of our C10, if you simply grid the protruding lip back to the body line the roof sheet metal will be thin and useless. What I found worked best was to cut the drip edge off leaving the pinch welded lip sticking out from the body.  Then use a flapper wheel to grind that lip back until you start to see a little separation between the layers.  Now, carefully cut the bottom of the sandwich out so only the roof metal is left sticking out a little.  That little protrusion can be hammered down to tightly fill the gap underneath while retaining the body line perfectly and leaving plenty of good metal to stitch together.

111 Degrees

It took six hours to trim and weld the drip rail over the windshield and it still need to be ground smooth to make it all pretty. All day long it was really hot. Around 2:00 pm I was pulling off my welding gear thinking, “I could probably use some water.” While I was standing there drinking the garage temp read 114. I noticed around 4:00 pm it felt like it may be cooling off. Well, I guess 111 in the garage is technically cooler.