I am looking to replace both cab corners on a 94 Dodge reg. cab pickup. Looks like they could be pulled apart at the seam @ rear of the cab & maybe inside the door jam area.
Any body have any tips on doing this??
I can weld & have cutting tools ect..., just not sure where to start or what to expect. Also was suggested to use some type of body glue rather than welding??
Thanks

Using the new corner as a guide, cut the old corner an inch or so below where the new one comes up to with a small cut off wheel. Drill the spot welds in the jamb, along the rocker (?), and behind the cab with a 1/8" bit then drill part way into the spot weld with a 5/16" bit to free up the spot weld.
Probably best to remove or at least move the box back a bit.
Remove the primer on the back side of the new corner and use weld thru primer there. Drill 1/4" or 5/16" holes where the factory spot welds were and plug weld them up. Stitch weld along the top of the corner. Repeat for the other side.
That ought to get you started.

Pretty mich what Wiley said. I will add, I usually trim them down so the weld seam is below the lowest body line (not sure what a Dodge looks like) This way the bodywork is below the bodyline and the body line also adds stiffness as you work on it. Don't weld it all at once, It will warp all to heck. Obyously if your rust is above the bodyline you will need to adjust to fit, Most of the time the rust is pretty low.

LK

Wiley,Alwhite00,
thanks for the tips on the corners.. What do you think about using glue rather than welding them on?? Should I make the upper part of the corner have a step flange so they overlap on the top part of the corner??
Thanks Again

I saw a guy on Trucks ( tv show ) put two cab corners on an S10 in the following manner. Laid new cab corner in place and traced around it with a magic marker. Then cut out rotted corner with a grinding wheel. With the hole following the shape of the new corners and maybe 1/8 to 1/4 inch larger on all sides he glued tabs on all four sides with the tabs protruding into the area where the new corners sat. He then just glued the new corners to the tabs and filled in the gap between the new corners and the existing metal with putty. Seemed like a pretty easy way to do the job and no welding was needed. As I recall the adhesive was available in three different working times. Maybe 5 minute set, 1/2 hour set and two hour set. Just need to have clean metal to bond to and supposed to bond like crazy.

What do you think about using glue rather than welding them on?? Should I make the upper part of the corner have a step flange so they overlap on the top part of the corner?

I wouldn't recommend gluing them on, but if you do, use a panel bonding adhesive with a slow cure.
I don't think that it's neccessary to use a step flange along the top. Once you've got the corner welded on, just tap it down a bit if you have to.
Also, as Alwhite00 says, trim the corners to what would work best if the amount of rust allows you to.