Now we can get down to some fun work. In all of the cases below the procedure was the same for fabricating each patch panel:
- Identify the extent of the damage
- Remove damaged area using straight cuts if possible
- Make patch panel template from cardboard stock
- Transfer template to sheet metal
- Plasma Cut, bend and form panel to match opening
- Clean and deburr
Installing the patch panel:
- Clean and dress the with cut area
- Place patch panel in opening and check fit – best case less than 1/16″ gap
- Hold panel in place using, clamps, vise grips or magnets
- Tack weld panel in middle of each side
- Remove clamps etc and check fit
- Stitch weld panel every 1″ or so, allow to cool
- Grind down each stitch weld until .005-.010″ proud.
- Hammer and dolly each weld until flat
- Place another stitch weld next to the finished weld when complete grind and hammer finish as above
- Repeat above until panel is completely welded in.
- If panel is exposed to where it can be seen, then metal finish until smooth, flat and properly contoured to minimize filler use.
Fabricating Patch Panel for the Floor
Fabricating Patch Panel for Rear Quarter Panel
Fabricating Inner Fender Panel Lip
Fabricating Patch Panel for the Rocker Panel
Installing the Rocker Panel Patch
Installing the Quarter Panel Patch
Installing the Door Sill Patch
repairing the B Piller Support
Installing the Passenger Floor Patch