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Making repair panels

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moonlite

06-03-2003 04:05:59




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I know there is an air tool for the job but need to recess a panel in the side of a truck door. I do not want to buy the air tool to make the panel fit flush. Any suggestions for using hand tools. Only one small panel.




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T_Bone

06-03-2003 07:40:28




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 Re: Making repair panels in reply to moonlite, 06-03-2003 04:05:59  
Hi moonlite,

Use Wiss M1 & M2 tin snips. Drill a 3/8" starting hole on the inside of your cut lines. First, Ruff cut the hole 1/4" away from the finish line by alternating using snips for a double cut.

After you ruff cut the hole then finish cut the line.

What this does is make it easy to remove the SM stress of the door panel so yoi can get an accurate cut.

T_Bone



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buck

06-03-2003 06:35:30




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 Re: Making repair panels in reply to moonlite, 06-03-2003 04:05:59  

weld an overlapping flange to the back of the area to be repaired and then weld your repair panel to that. Narrow straight strips of sheet mtal work fine for doing this.



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rossow (mn)

06-03-2003 04:52:54




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 Re: Making repair panels in reply to moonlite, 06-03-2003 04:05:59  
You probably already know that hand flangers are available for flush panels. They're like a Vise Grip pliers with jaws that create flanges. You can sometimes get cheap versions at Harbor Freight. They work as well as the air ones, just not as fast. Without a flanger, I'm not sure how you can create a flange smooth and even enough to work.



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Rusty Jones

06-03-2003 12:48:00




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 Re: Re: Making repair panels in reply to rossow (mn), 06-03-2003 04:52:54  
Some advice from an old auto body man: Get a couple bed rails from a sleeping bed. at each end are holes. Put a bolt and nut assembly thru one end, thru both rails, then tighten until you can just swivel the rails. Place the sheet of tin in between the rails, clamp the whole thing in the bench vise, clamp along it with vise grips and/or clamps, about 4 inches apart! This makes a sheet metal brake! Now, before you clamp the tin in it, measure and mark off 3/4 inch from the edge, on the tin. Then between that mark and the edge, make another one 5/8 inch from the edge. Now, clamp the tin in the brake on the inner mark,(3/4 in.) and bend the edge down 90 degrees. Take the panel from the vise, lay the panel along the edge of the rail, with the short right angle of the panel on the edge of the rail, clamp it at both ends, with the 5/8 inch edge mark on the edge of the rail. then carefully bend the tin down at a right angle. This will give you the correct "joggle" on your panel. This edge will be on the same plane as the bigger part of the panel. Some care must be taken when hammering, but it can be done! You should use 24 guage tin for this work! Remember, you must have a bunch of clamps or vise-grips to hold the panel between the rails. You can find those rails in the trash! Folks throw them away quite frequently. you'll have to take off the legs and wheels. Want to know anything else about body work, write me! Yours: Rusty Jones

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Chester

06-03-2003 13:37:03




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 Re: Re: Re: Making repair panels in reply to Rusty Jones, 06-03-2003 12:48:00  
There is also a panel flanger made to fit those cheap and dirty air hammers for around $15. I took one and vise mounted it and added a lever in the rear to pull down on the offset die. Works really well , with no noise and my panels are usually 18ga.



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