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    1. #1
      Join Date
      Dec 2007
      Location
      British Columbia, Canada
      Posts
      723
      Country Flag: Canada

      Tip for making small panel patches

      I know there are lots of great fabricators and body guys on this site, none of which would ever need any advice from a guy like me, but I thought I would share a tip a discovered today,all because I was lazy the other day.

      This is for anyone who had a hole in a panel that they needed to fill in with more sheet metal. I'm sure a lot of us have sat there cutting and testing, cutting and testing until finally the filler piece is the right size. Sometimes it may take several attempts, but eventually we make it. Today I was doing some more work on smoothing my firewall now that I now I will be using a drive by wire throttle. I cut out the area I wanted to smooth and started looking at the hole I had to fill trying to figure out the best way to make a template. I happened to look over on the floor and saw a roll of masking tape that I was too lazy to pick up the other day and it gave me this idea.

      I thought of taking pics after I had the tape on, but you'll get the point.

      The area I wanted to fill in was the pedal holes to the left of the steering column hole.



      Once you have the hole cut, cover the entire hole with masking tape.



      I used an exacto knife to cut along the sides of the hole



      I then stuck the newly cut piece of tape to some sheet metal giving me my template



      If you cut it along the side of the tape, it will be the about the same size of the hole. Since I wanted to butt weld it, I cut a little smaller than the tape



      Take the tape off and you have your patch



      Tack it into place. The nice thing about trimming a bit smaller than the tape was it left me nice gap to fill in with weld



      Finish your welding



      And finally after some clean up


    2. #2
      Join Date
      Dec 2004
      Location
      Midwest
      Posts
      2,261
      Country Flag: United States
      That is a good trick. Saves time over cutting a piece of cardboard, trimming it, transferring the design to steel, trimming it, seeing that it doesn't fit, trimming more, then getting it right.
      Kevin Oeste
      V8 Speed and Resto Shop
      V8TV
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    3. #3
      Join Date
      Nov 2006
      Location
      Mountain Springs, Texas
      Posts
      4,488
      Country Flag: United States
      That is a great tip. Thanks.
      1969 Camaro - LSA 6L90E AME sub/IRS
      1957 Buick Estate Wagon
      1959 El Camino - Ironworks frame
      1956 Cameo - full C5 suspension/drivetrain
      1959 Apache Fleetside

    4. #4
      Join Date
      Jul 2005
      Location
      Mountain View, CA
      Posts
      9,583
      Country Flag: United States
      You know those moments in life when you see something and think, "geez I am such a spaz, why didn't I think of that?". I'm having one of those right now.

      Great idea man.

      Sticky material.
      True T.

      Whats new with Project 1/2-Trak?


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    5. #5
      Join Date
      Nov 2008
      Location
      TN
      Posts
      938
      Looks good! great idea!
      Benjamin

      Twin Dusters
      '72 Plymouth Duster "Aero Duster" project
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    6. #6
      Join Date
      Jun 2001
      Location
      Orlando, FL
      Posts
      10,603
      Country Flag: United States
      I've done this myself, and it is a good way to transfer a "void" to a piece of sheetmetal. Nice writeup.

      One comment about putting a gap in the patch panel. You're right that it makes getting full penetration welding a lot easier, but it also puts stress on the patch and surrounding sheetmetal. When the weld is applied, the metal in the joint is liquid. As the joint solidifies, it shrinks, and pulls the metal edges closer together. In a firewall, it won't matter, but on exterior sheetmetal it will cause warping.

      jp
      John Parsons

      UnRivaled Rides -- Modern upgrades for your ride.

      UnRivaled Rides recent project -- LS9-powered 69 Camaro

    7. #7
      Join Date
      Jul 2005
      Location
      Mountain View, CA
      Posts
      9,583
      Country Flag: United States
      So when filling for instance, a side marker light, you'd want the tightest fit possible between the patch panel and the fender?
      True T.

      Whats new with Project 1/2-Trak?


      Follow my wisecracks on Sports, Food, Politics and other BS on Twitter.

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      When they kick out your front door, How you gonna come?
      With your hands on your head, Or on the trigger of your gun?

    8. #8
      Join Date
      Jun 2001
      Location
      Orlando, FL
      Posts
      10,603
      Country Flag: United States
      Quote Originally Posted by True
      So when filling for instance, a side marker light, you'd want the tightest fit possible between the patch panel and the fender?
      Exactly. The welding is harder, since more heat is needed to get full penetration, which means you need to take more time when welding. Watch and make sure the metal edges stay lined up, take your time, and work in a methodical way. It will make a big difference in the amount of distortion you induce.

      jp
      John Parsons

      UnRivaled Rides -- Modern upgrades for your ride.

      UnRivaled Rides recent project -- LS9-powered 69 Camaro

    9. #9
      Join Date
      Jan 2009
      Location
      Cary Illinois
      Posts
      25
      What a easy solution...i trim, fitup, and trim some more. Great idea!

    10. #10
      Join Date
      Feb 2008
      Location
      Sugar Land, TX
      Posts
      120
      That's a great idea! Thanks for the tip.
      StephenL
      1967 Olds Cutlass Supreme

    11. #11
      Join Date
      Feb 2006
      Posts
      478
      Man, this is the best tip I have gotten in a long time. It came at the most opportune time too! I have been patching all the holes in my firewall for a smoother look, like the old electrical bulkhead, and the grommet holes and so forth. This tip works far better than any other way you could do it.

      Thanks for the tip scherp69 and thanks Pro-Touring.com!
      Alex Godsey
      Somerset, KY
      Pro Touring 67 GTO
      461 Pontiac Power

    12. #12
      Join Date
      Apr 2001
      Location
      Rockford Illinois
      Posts
      3,947
      Country Flag: United States
      Don't forget to buy one of those welding magnets with all of the angles on it. You use the magnet to hold the piece flush while you tack it in. These things are priceless and come in many sizes.

    13. #13
      Join Date
      Oct 2008
      Location
      Roseville
      Posts
      286

    14. #14
      Join Date
      Jan 2008
      Location
      Perth Western Australia
      Posts
      233
      Country Flag: Australia
      Quote Originally Posted by camaro2nv View Post
      Awsome little tool I use them all the time.

      Greg
      Used to be known as tonner

    15. #15
      Join Date
      Sep 2004
      Location
      Near Dayton, OH
      Posts
      547
      Quote Originally Posted by camaro2nv View Post
      I have set of those and they work really well. Bought them from Eastwood. However, after seeing that my local Harbor Freight sells the same dumb things for $5 I'll never spend the ridiculous $30 that Eastwood wants for them. Especially when you get 8 instead of just 4.
      Andrew
      1987 Olds Cutlass Supreme FE3X Clone
      EFI455/T56/9" w/ 4.30 gears
      __________________________________________________ __


    16. #16
      Join Date
      Mar 2008
      Location
      Ramona, Ca. San Diego area
      Posts
      1,307
      Country Flag: United States
      Quote Originally Posted by BigBlockOlds View Post
      Harbor Freight Eastwood.
      exactly
      67 Camaro convertible (Jinx)

    17. #17
      Join Date
      Aug 2004
      Location
      Rustburg, Virginia
      Posts
      3,436
      Country Flag: United States
      Quote Originally Posted by BigBlockOlds View Post
      I have set of those and they work really well. Bought them from Eastwood. However, after seeing that my local Harbor Freight sells the same dumb things for $5 I'll never spend the ridiculous $30 that Eastwood wants for them. Especially when you get 8 instead of just 4.
      Do you happen to know what the HB product number is or what name Harbor Freight gives these doodads....didn't see them on their site while searching
      1970 RS/SS350 139K on the clock:
      89 TPI motor w/ 1pc rear seal coupled to a Viper T56 via Mcleod's modular bellhousing w/ hydraulic T/O bearing from the Viper, 12 bolt rear w/ 3.73 gearing, SC&C upper control arms, factory lowers with Delalums, C5 brakes at all four corners, Front Wheels 17x8's with Sumi 255/40/17 and Rear Wheels 17x9's with Sumi 275/40/17.
      Brief description of the work done so far can be found here: http://www.nastyz28.com/forum/showthread.php?t=112454


    18. #18
      Join Date
      Sep 2004
      Location
      Near Dayton, OH
      Posts
      547
      I haven't been able to find them on their website either. I just happened to see they carry them in their retail store once when I was in there.
      Andrew
      1987 Olds Cutlass Supreme FE3X Clone
      EFI455/T56/9" w/ 4.30 gears
      __________________________________________________ __


    19. #19
      Join Date
      Dec 2005
      Posts
      40
      I have lots of panels like this can you come do em for me .... ;)
      69 SS396 Camino 540 FAST EFI BBC
      http://profile.imageshack.us/user/peetsjunkie/images Check out the latest stuff here!

    20. #20
      Join Date
      Mar 2008
      Location
      Ramona, Ca. San Diego area
      Posts
      1,307
      Country Flag: United States
      Quote Originally Posted by John Wright View Post
      Do you happen to know what the HB product number is or what name Harbor Freight gives these doodads....didn't see them on their site while searching
      I was just at HF the other day and I seen them in the welding section. Plenty in stock.

      67 Camaro convertible (Jinx)


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