how to replace cab corners without welding

How to Replace Cab Corners Without Welding

Cab Corner Replacement

If you own a truck or a vintage vehicle, chances are you’ve encountered rusted cab corners at some point. Replacing these damaged cab corners is crucial to prevent further rust and structural issues. While welding is commonly used for this repair, not everyone has access to welding equipment or the necessary skills. Fortunately, there are alternative methods to replace cab corners without welding. In this article, we’ll guide you through the process.

Tools and Materials You’ll Need:

  • Screwdriver or drill
  • Sheet metal cutter or angle grinder
  • Rust converter
  • Power drill and rivet gun
  • Metal adhesive or epoxy
  • Primer and paint
  • Protective gloves and safety goggles

Step 1: Removing the Rusted Cab Corners

Start by removing the old cab corners using a screwdriver or drill. Make sure to detach any screws or bolts holding them in place. Once the panels are free, carefully pry them away from the vehicle’s body. Take your time to avoid damaging surrounding areas.

Step 2: Preparing the Replacement Panels

Using a sheet metal cutter or an angle grinder, cut the replacement panels to match the size and shape of the original cab corners. Measure accurately to ensure a precise fit.

Cutting Replacement Panels

Step 3: Treating the Metal and Applying Adhesive

Before installation, treat the replacement panels with a rust converter to prevent future corrosion. Follow the manufacturer’s instructions for application. Once dry, apply a strong metal adhesive or epoxy to the backside of the panels. This will help secure them in place.

Step 4: Attaching the Replacement Panels

Position the replacement panels over the old cab corners and press firmly to ensure proper adhesion. Use a power drill and rivet gun to secure the panels by drilling evenly spaced holes along their edges and inserting rivets. This will provide additional support and strength to the repair.

Riveting Replacement Panels

Step 5: Finishing Touches

After the replacement panels are securely attached, it’s time for the finishing touches. Apply a coat of primer to protect the bare metal, and once dry, paint the panels to match your vehicle’s color. This will give your cab corners a seamless look.


Replacing cab corners without welding might require some patience and basic DIY skills, but it’s certainly achievable with the right materials and tools. By following these steps, you can restore the appearance and structural integrity of your vehicle without the need for welding equipment. Remember to prioritize safety by wearing protective gear throughout the process.

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