first - after studying the truck pics and trying to find pics of the truck kits without all the shiny bits I settled on an Aeromax kit. You might think Im nuts but I think they are pretty close resemblences .......
SO got the kit started assembling the basic major components. Axels, front axel, transmission mounted the cab.
Then popped up the trusty PC and printed pic after pic of the orange truck front and side views (hard to find - had to settle on a 1:1 rear ytuck in profile) until I had the door height about same relative size.
Then started cutting on the cab - determined that the aero has more upper curve (facing straight on) so decided to start there.
also decided that the "cut in" at the door front to the cab was too severe so I lessened that - also helped square up the cab
The cuts allowed me to flex the upper door and A piller up straight. I measured and made a thin inner panel to cap off the Cab - made sure this squared up the cab at the back as I wanted and glued it in. Then mounted a pice running like it's under the dash to hold the front of the cab close. Notice that I left the sleeper attached - it helped hold the cab nice and square so it didn't flex out of shape when I was flexing and such.
The top of the CAB is two colors - I had picked up a salvaged cab some months ago - had been thinking about doing a sterling. But since the top is now larger I need more roof pieces. Rather than just cutting down the center I cut along each side. The cut out the donor cab in the same way. Then I measured and sandwiched the two cab pieces together and cut down the middle - using just over half of each cab roof section. Then match the lines and trimmed pieces to fit.