Body Panel Repair/Replacement on M38

rgmutchler · Post by **rgmutchler** » Mon Dec 12, 2011 1:03 pm

I have disassembled the cowl, lower cowls and cut out the floor/firewall and am in the process of removing the spot welds that hold the remainder of the floor to the rear quarters and across the end of the bed.
I have noticed some things that I wanted to get the opinion of some of you that have been here before. I have included some pictures that will hopefully explain what I am talking about.

1. I have removed the entire lower cowl from where it meets the quarter panel on the left side. It was easy to see the line where the lower cowl over laps on the side. However I wasn't sure if part of the upper edge of the quarter panel was left to fit inside the new lower cowl or if it all gets cut off even with the vertical line. I looked on the web at pictures of replacement cowls and saw that most showed a straight vertical line and one or two showed the top edge of the quarter panel extending past the vertical line where they join. The replacement quarter made by Classic Enterprises is one that shows the upper channel extending past the vertical line. Which is right?

2. I noticed that there is a u shaped piece of metal spot-welded in the top channel of the lower cowl and the quarter panel. Is this piece available and is it possibly the part I see extending forward past the vertical line between the lower cowl and the quarter panel. I have left some of the top lip of the quarter panel extending forward and it can be seen in the picture.

3. The joiner gusset. Mine are/were cut up and bubba-ized. The one on the left was welded up in the top channel of the (inside) of the junction between the two panels. The one on the right is welded at the top edge of the top channel at the junction of the two panels. I have access to one other M38 body that is in good shape and it showed the gusset put on in the same manner as described above. Is this correct?

I am sure that there are other things I should be asking but I'm not smart enough to know how much trouble I am in.

evanso1975 · Post by **evanso1975** » Mon Dec 12, 2011 2:18 pm

1. I have removed the entire lower cowl from where it meets the quarter panel on the left side. It was easy to see the line where the lower cowl over laps on the side. However I wasn't sure if part of the upper edge of the quarter panel was left to fit inside the new lower cowl or if it all gets cut off even with the vertical line. I looked on the web at pictures of replacement cowls and saw that most showed a straight vertical line and one or two showed the top edge of the quarter panel extending past the vertical line where they join. The replacement quarter made by Classic Enterprises is one that shows the upper channel extending past the vertical line. Which is right?

Not 100% sure. Mine finishes flush. I have to say that every original bodytub I've seen (mainly WW2 jeeps) has had weld repairs at this location; probably a weak point. Extra reinforcing here would make a lot of sense. Check out the 6th photo from the bottom on this web page:

http://www.cj-3a.com/body_work.htm

There's quite a few helpful photos on that site, btw. I know its a CJ site, but the 3A bodytubs are very similar to the M38's.

2. I noticed that there is a u shaped piece of metal spot-welded in the top channel of the lower cowl and the quarter panel. Is this piece available and is it possibly the part I see extending forward past the vertical line between the lower cowl and the quarter panel. I have left some of the top lip of the quarter panel extending forward and it can be seen in the picture.

I've never seen it for sale, but it should be pretty easy to fabricate. If you don't have the facility to form the tight bends, you could always weld up 3 bits of steel to suit. Or just put some 1/8" plate inside there instead.

Maybe you can drop LaMonte at Classic Enterprises an email? He should be able to confirm if that channel is what's shown on the panel on his website.

3. The joiner gusset. Mine are/were cut up and bubba-ized. The one on the left was welded up in the top channel of the (inside) of the junction between the two panels. The one on the right is welded at the top edge of the top channel at the junction of the two panels. I have access to one other M38 body that is in good shape and it showed the gusset put on in the same manner as described above. Is this correct?

On my tub, the driver's side gusset is welded inside the channel, and the passenger side gusset is welded outside.

I initially thought the passenger side one was wrong, but the picture of page 148 of Ryan's reference guide shows it welded outside the channel too. So I guess it's correct.

Good luck,
Owen.