Who has repaired rusted kickpanels?

[guhfluh]

I know the kickpanels are a common rust through area in these trucks because of the debris that collects behind there in the fenderwell area, but I haven't been able to find more than one picture of someone repairing them.

Mine are both rusted through pretty bad, as well as a small hole in the passenger floorboard. My problem is that I don't know how to weld and don't have a welding machine. I'm very close to buying a Lincoln 140 just for this truck and teaching myself how to weld, but that's in the future.

Anyone have any experiences, suggestions or especially pictures of your kickpanels repairs?

[cep62]

Well if you have the ambition to learn, I'd buy the equipment and learn to use it.

or take that money and pay someone else.

[67nukeford]

I'm in the process of doing this. I've got my cab off of the truck, and I'm removing the panels that enclose the vents on the cab sides. Eventually, I'll be removing the cowl, also. But, the drivers side kick panel is in pretty bad shape. the back side is badly rusted, and it has rusted through at the bottom. My plan is to clean up as much of the rust as possible, then start replacing the sheet metal. This might be tough to do without going as far as I am, depends on where/ how bad the rust is in your kick panels. I'll see if I have some pics of what I have on the backside, and post them up tomorrow.

[guhfluh]

My floor pans are fine, except right where they meet the kickpanels. On the pass side I have two pinholes there. The kickpanels have fairly big holes, but only right at the bottom where they meet the floor. My truck is kinda strange how localized the rust is. I would have thought the kickpanels would have rusted through from the vents being 6" full of rat nests and years of rotting, wet plant debris built up in there, but that area is fine, as are the rest of the floor pans.

I am contemplating a poorly done patch job with sheetmetal screws and body seam caulk, until I can get it welded up right and painted, I just hate doing it halfassed, but I need the holes filled to plug the water leaks now.

I'll take some pics of the current state and post them so you can see.

[67nukeford]

That whole area down there is a pain, since 3 panels are welded togther (rocker, floor, kick panel). I had to rebuild the front of the rocker on the drivers side, and the bracket to hold the nut that attaches the fender. I wish I could have found a better cab, but most of them here are in evern worse shape!

[guhfluh]

[jimmy828]

Well if you have the ambition to learn, I'd buy the equipment and learn to use it.

or take that money and pay someone else.

That's what i done . Purchased myself a welder and learn enough about it to replace certain areas in truck. The kick panels was the first thing.

[undertakerman]

I have just replaced the passenger side kickpanel from the vent down, the lower corner of the firewall and part of the floorpan. The photo of the kickpanel shows the work involved in replacing it. And the other photo shows the final mock up before prep and installation including the floor panel. The other photo shows the firewall repair along with the panel gutter replacement trim and final mock up before final prep and installation. Every piece except for the floorpan had to fabricated. When everything is complete I will post photos so you can see how it turned out. Hope these photos help you see what you will need to do. I did what others have say. Buy yourself a Lincoln Mig Welder, a 4 foot square piece of 18 gauge, snipes and a hand shear made to cut 18 gauge and teach yourself how to cut and weld. I did it 11 years ago and I'm still learning. Good luck with your project.

[Whateverman]

good reason to buy a welder and learn to weld...its the same reason i decided to learn to weld ..and became a welder.

before that happened i did a self drilling screw, rivet and (marine)caulking repair with a couple of chunks of tin from an old fridge door which held up fine until the floor rotted away

as previously stated there are 3 layers of sheetmetal in the floor in that area..its a pain in the butt regardless of whether you weld in new metal or screw/rivet it together (get ready to break some drill bits)

you'll find that the rust in the floor section actually extends much further than you would expect (anywhere from 2 to 8" in the 4 cabs i've done)...buy or borrow a chipping hammer and do some smacking around on the floor with the pointy end --its pretty shocking sometimes...be prepared to do some floor pan repair as well

goodluck!

[67nukeford]

Bought a bead rolloer from Eastwood, to make that little flange on the kick panel patch, where it spot welds to the door frame. Came out perfect!

[67nukeford]

Here is what I ended up patching....

[67nukeford]

Drivers side is in

[guhfluh]

Thanks for the pics guys!

[Ftruck Fan]

Did you guys remove the cowling before attempting this repair or just take off the fender?

[lloyd399]

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