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Re: Replacing truck bed sides


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Posted by Mike in Mn. on November 29, 2014 at 20:11:10 from (74.46.182.73):

In Reply to: Replacing truck bed sides posted by G1355 on November 29, 2014 at 17:20:51:

Cut the rusted area out of the quarter, make sure it's a smaller area than the patch panel. grind the area you are going to cut so you can weld on clean steel later. Then cut the patch panel to fit. The best is to flange the panel and cut the patch to fit in the flanged area, you can make a flanger out of a pair of vise grips like in the picture JD posted(I made my own, nothing to it)or you can buy one. You want a 3/4 inch flange. You want the flange in on the quarter so your patch will lay even with the surface of the origional quarter, practice on some scrap till you get it right. Drill 5/16 holes around the patch every inch apart, fit the patch into place and drill every other hole for a #8 by 3/8 sheet metal screw, start in the middle and work your way out. With the patch screwed into place the way you want it start wire feed welding into place, plug weld the holes and weld the seam, naturally about an inch at a time to not warp the panel. When done remove the screws and weld those holes making sure you get the screw holes in the origional panel welded nice, this will give you a nice lap seam that will be strong. Grind, clean the welds and then use Duraglass for the first coating of bondo, Duraglass is strong and waterproof but keep it low cause it is hard to work and finish with your favorite Bondo. I have done many wheel well patches like yours and lower quarters this way and have had very good luck with not warping a panel, have some jobs out there for years and they still look good. If you can get to the back side of any weld protect that also with a good sealing product. Hope this makes sense to you.


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