Well, theres some good info here, thanks!

For spot welds, I know there are actual spot welders, but uh, I don't have one so I think I'm just gonna be trying to use my 110 MIG to do little "spot welds".  This will work, right?  Just might not look as clean in the long run?

I plan to square everything up like you said, then weld, then primer and paint it.  Just rattle can most likely since it will mostly be hidden stuff (core support).  The inner fenders (aprons?) are good, its just mainly the core support that needs to be replaced.  The inner fender on the drivers side was crumpled a little in a couple spots, but I was able to get it straight again with a hammer and a dolly thing.  I took some rough measurements and ran some strings and it seems both inner fenders end at the same point as measured from the firewall where they would meet the core support.  I'm thinking I just have to get the core support panels back on, make sure its square and be done with it.

For the actual panels (hood, fenders), Ill be spraying real automotive paint.  Err, trying to anyway, haha.  My uncles have done frame off restorations so I'll be consulting them along with reading up on it.  I'm also going to use certified panels, but not OEM.  Hopefully they work out decent.

As for the core supports and grill pieces and stuff, those are aftermarket.  The cost of OEM is WAY too much on all the panels since shes not getting much back from the insurance to fix it unfortunately.  I'm hoping that they're good enough I can get it to line up and look good.  The truck really didn't have much damage at all, so I think it should work out pretty well actually.

Im not trying to make a show truck, but I dont want you to look at it and obviously be able to tell it was rebuilt for the most part.  Im somewhat of a perfectionist, so I'll do it over and over again until I can get it right, which will probably be my curse, haha

We're also doing some upgrades and preventive maintenance while its apart though.  Shes getting a new electric fan to go with the new 3-core radiator (stock), new radiator hoses, a new gel cell battery, new front cover, new timing kit with metal rails, new oil pump, new water pump, new oil pan gasket, fixing an exhaust leak from the PO, etc.  Most likely it will get a new custom tube bumper too rather than the stock bumper.

~T.J.