Panel patching...

[layedout72]

Alright, as we all know, all of our trucks need a bit of body love. Mine went anorexic in a few spots and ate its own self a bit, and lost a little shape in other areas. I am looking at patching both lower door skins, front lower section of the bed, and floors. MY question is, when doing the doors, how do I go about it? I know the bed is pretty much trace the new part, cut it off, weld it back. But the doors, how do I go about this? Keith, I know you just did this, any chance of sharing some knowledge?

[FORDification]

That depends on whether or not you've got replacement doors to donate patch panels or whether you're using replacement patch panels (skins) from an aftermarket source.

I just replaced a lower door skin, from the bump down. I was able to salvage the entire lower skin from a good replacement door (but couldn't use the whole door since it was for the choptop truck). I just uncrimped the skin all the way around the door perimeter on the sides and bottom and then cut across right at the bump valley. I've got some pics posted at the following URL:

http://www.fordification.com/mychoptop-p05.htm

With an aftermarket patch panel is simply a matter of cutting out the rust, trimming the patch panel to fit the hole you created and then welding it in. You'll need a MIG welder with shielding gas (for best results...or a TIG, if you're rich), and then just run very short beads in alternating spots around the perimeter of the panel to minimize heat buildup which will cause warping. After every short bead, use a wet sponge to quench/cool the weld.

If you're planning on butt-welding the panel, I'd suggest getting some of Eastwoods panel alignment clamps, which will do wonders in keeping things lined up and held in place for you while you're welding in the patch panel:

http://www.eastwoodco.com/shopping/prod ... uctID=1159

An alternate method for butt-welding is to flange-weld. You can get a flanging tool very inexpensively which will crimp a stepped flange on one of the panels, where they can overlap for the weld. However, since it's easier for moisture to get in-between two overlapped panels, you really need to be sure to completely seal it up on the back side.

Here's a manually-operated flange tool:

http://www.eastwoodco.com/jump.jsp?item ... pe=PRODUCT

...and here's a pneumatic version (which I have), and which also includes a punch tool, to punch holes in the panel for welding:

http://www.eastwoodco.com/jump.jsp?item ... pe=PRODUCT

[fordman]

how on earth did you uncrimp a door skin.

[FORDification]

how on earth did you uncrimp a door skin.

I described how in detail at the link posted above.

[layedout72]

thanks keith. I think I will be building a welder/bottle cart this weekend, and possibly buying my gas as well. Might even place some orders for my epoxy primer and patch panels

I am going to order them from LMC, so I guess that they would be a good quality build.

[foghorn]

I have seen that type of flangers before but the one i had back in my dads shop was used with the air hammer. I will see if i can find a pic of one.



Foggy

[layedout72]

i dont have any trucks to cut off of.