Rust repairs/panel fab

[dirtbag]

Hiya. Here's a repair I did on an HK monaro a little while back.




Here's the new outer skin I made.






And here it is welded on. For areas like this I tack the panel in with the mig, then use the oxy to fully weld it.





You've gotta love rust repairs : )

[turbosigma]

Not my work - friend doing it for me.









Need to pop the windows out and finish it.

[ChrisS]

I'd love to see some step by steps from you talented lot on how you get flat bits of metal to these shapes! Fucking beats me how you do it!

Best advice I ever got was it's only metal, if you fuck it up then just do it again!
Just give it a go, do some youtube searches and get some basic metal work tools.

Start off with simple stuff so you get the idea of how metal moves around and work from there, don't try to get it perfect the first time around.

I use thin cardboard, lay it over the panel to be replaced and make a template, cutting "V" shapes here and there to get it to follow the curves. Then transfer the template to sheetmetal and go from there. On the rear 1/4 of the 180B you can see where I've cut a few long, thin "V"'s, brought the edges together and welded. This gets the shape happening, and I finish it off with hammer and dolly. I also tend to work with a few smaller pieces and weld then together for a large patch.

The inner piece with the pattern pressed into it was made by routering the pattern into a piece of wood, the hammering the metal into the wood with rounded bits of metal and large drill bits.

Its all welded with oxy, so I use very little or no filler. also leaves a nice, soft, "annealed" panel that is easier to work with hammer and dolly than a MIG welded repair.

I've just got the DVD ChrisS recommended in another post and hope to be able to master beating stuff out of a single piece of metal rather than a few cur and welded pieces.

That DVD is fucking awesome!


I'm about to start some serious metal work on the Pick Up so will post post up soon.



BTW some nice work shown already, keep the picks coming!

[charade_16v]

This looks like top notch work!
I'm looking for someone in the Sydney area to duplicate part of my inner guard of a 1971 KE20 corolla.
My plan is to cut the piece out (it's fairly rusted) and bring it to the person, they duplicate it, then I can weld it back in myself.

Any help is greatly appreciated!

Cheers,
Mark

[Gammaboy]

I'm an amateur.

[garvice]

Thought I might revive an old but good thread. Been doing some repairs on my 1600.
Latest panel before



after



Car build thread here
http://performanceforums.com/forums/...82622-Gas-1600

Some info on how I made the panel here
http://www.the510realm.com/viewtopic...=25090#p213037

[BigMuz]

Very nice.

[ChrisS]

Nice effort, list of tools used?

[Lurch]

I suppose I can add to this thread, showing my meagre skills...

Mates Mk1 Escort 2-Door restoration that I'm doing the tin-work on:

Firewall had bad cancer:














I might start a build thread once it's painted...

[garvice]

Looks neat Lurch, love the spot welder.
What was the massive hole in the top of firewall for? Was that air intake for cabin?

Nice effort, list of tools used?

Chris, I used a couple of different body hammers/slappers, toe and utility dollies, couple of home made chasing tools and forms, bunch of clamps and MAP gas. Nothing fancy.

You can see all the tools I used in the link I left above, again below in case it was missed.

http://www.the510realm.com/viewtopic...=25090#p213037

[Lurch]

Looks neat Lurch, love the spot welder.
What was the massive hole in the top of firewall for? Was that air intake for cabin?

Yes, heater box air intake Brad

[gerry]

http://retrorides.proboards.com/thread/70135/panels#

here is a how to..

[garvice]