So I bought this one today.

[Samplingman]

And here’s what happens when a carpenter with limited metal forming tools is tasked with forming a complicated patch panel.

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I can see a whole industry in making and selling these forms for hard to find patch panels. Nice work!

 

[OldWarHorse300]

"And here’s what happens when a carpenter with limited metal forming tools is tasked with forming a complicated patch panel."
Lol, welcome to my life!
Absolutely fabulous work and great idea that American wheel!

 

[Boydsdodge]

I haven’t welded it in or even cut the old one out yet but it looks like it will fit very nicely and it’s repeatable!
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I wondering if using one of the space saver spare tires would concentrate the pressure. Those spares have very hard rubber and a narrow foot print.

 

[3175375]

And here’s what happens when a carpenter with limited metal forming tools is tasked with forming a complicated patch panel.

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I will probably do that too.

 

[3175375]

I wondering if using one of the space saver spare tires would concentrate the pressure. Those spares have very hard rubber and a narrow foot print.

Plus higher pressure

 

[Zymurgy]

I call it the American wheel.
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Love it, and it takes up no more floor space compared to the English wheel.

 

[Figgy]

Love it, and it takes up no more floor space compared to the English wheel.

Yeah but the English wheel gets better gas mileage.

 

[detmatt]

I wondering if using one of the space saver spare tires would concentrate the pressure. Those spares have very hard rubber and a narrow foot print.

Actually my brain was going the opposite direction. I was thinking about letting some air out of the tire before rolling it over the form but in the end I didn’t and it worked as I thought it would.

 

[live4theking]

You're more than a carpenter.

 

[detmatt]

Got the repairs done in the trunk floor and the welding finished on the outer wheelhouse. Now on to the repairs and prep of the patch panel assembly.

 

[3175375]

Got the repairs done in the trunk floor and the welding finished on the outer wheelhouse. Now on to the repairs and prep of the patch panel assembly.
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Good work!

What are you using for the plug weld punch?

 

[detmatt]

Good work!

What are you using for the plug weld punch?

For drilling apart the factory spotwelds I use Blair spotweld cutters.

 

[3175375]

For drilling apart the factory spotwelds I use Blair spotweld cutters.

What about drilling new holes?

 

[detmatt]

What about drilling new holes?

Just a drill bit.

 

[detmatt]

First patch on the replacement panel.

 

[detmatt]

This one is next.

 

[detmatt]

Here’s the piece fabricated, just need a little more prep on the panel before I weld it in.

 

[detmatt]

I thought this one was going to be tricky but it was easy and turned out great. Just need to dress the welds.

 

[crv]

Very ingenious.

 

[detmatt]

The lower part of the trunk floor extension(drop) was/is badly pitted with a couple of dime sized holes and several smaller holes and since it’s currently open on both sides now is the time to deal with it.
I decided to change it up a bit and try a different process in this area.
I first put a steel wire brush on the grinder and thoroughly hit the rust and scale on both sides with it. Once there was nothing even remotely loose left I put several thin coats of SEM Rust Mort all over any area on the whole replacement panel that had pitting or surface rust that didn’t warrant patches. I then filled all of the holes with welds. Once all the welds are dressed everything will be treated again with Eastwood Fast Etch before being top coated and sealed.
So remove and convert the rust, clean with Pre Painting Prep and seal with the appropriate top coat for each area.
I will do the same process on the car in the areas behind and around this panel.