Can I fix this by cutting out and only replacing outer?

[OldBlueDually]

Too bad we don't live closer, I'd be willing to help you out! To expand on what @TotalyHucked stated the welding can do some warping. However, a quick tack, then opposite end of panel another quick tack....basically all over the place jumping around until done would help this to not happen, but takes some time as you gotta let it cool and not over do it.

What I do suggest unless you have a good 220 welder that penetrates well is to use the two part epoxy that's available and as strong as a weld. Look it up, and you should get a flange tool (similar to this one, for making a flange on existing steel for patch panels to sit against https://www.eastwood.com/ew-panel-flanger.html ). Make the crimp, apply epoxy, and clamp accordingly to hold it.

When cured, finish off the bodywork and paint it.

I actually plan to do the above (2 part epoxy) with our 2001 3/4 Suburban rear passenger rockers because I don't want to make extra work for myself with welding, nor start any fires because I'm not ripping out carpet etc. and this way I can also coat the inside of the existing and new rockers to prevent future rust and not worry about burning it off with welding.

 

[OldBlueDually]

Oh, here is that puller I have I mentioned earlier. Works awesome.

You must be registered for see images attach

 

[justhorns]

Thanks all, I got what I need. This is a great place to help plan a project, among other things..

 

[Scott91370]

A new bed Side, or a new Bed?

Side. Its a couple dozen bolts and some seam sealer.

 

[Grit dog]

You could buy a rear section patch panel and an over the fender patch and still have a bunch of body work to do, but it would be only 1/4 -1/3 the cost of a bed side.
Bed side is a slam dunk as mentioned earlier.
But if not that or not a new bed, you mentioned “didn’t need to be pretty”. You being a classic car guy, not pretty is horrible if it’s ugly body work. I’d leave it like it sits before having a 50’ body work job.
Since you’re not in a hurry, keep your eye out for a bed. Eastern CO is likely where you’ll find one.

 

[Grit dog]

Oh, here is that puller I have I mentioned earlier. Works awesome.

You must be registered for see images attach

I almost did something like that but only had a couple smaller dents that needed pulled to keep from piling on the bondo. I just tacked a little eye bolt on, hooked a piece of tie wire to it, bout 2’ long wrapped around a big wrench on the pulling end. Did the trick.

 

[TPISly-C10]

bed side are easy to swap!

 

[justhorns]

What I did not realize as the inside of the bedside is sold integral with the outside! Like I said. If you cannot fix a chevy square body, you should sell your tools.

 

[coolpup32]

I havent seen it mentioned... but there is one weld near the tailgate, otherwise bolts

 

[justhorns]

I havent seen it mentioned... but there is one weld near the tailgate, otherwise bolts

Yup!