Can anyone on this great site give me some ideas please. I have a 51 F1 and it needs the cowl patched. The question is.... who makes a panel that is big enough 15 inches/more (bottom to near heater knock-outs) and actually fits? I have zero panelwork experience, so everything will be a challenge.
Thanks in advance for any and all answers. I'm sure I'll be back with more questions.

 

Can you post some pics of the damage?

Classic Haulers has them, if they are what I am thinking you are talking about.

I just got floor pans from them, Made in the USA. Nice heavy gauge steel and appear to fit great. Im assuming that the cowls will do the same.

 

One good thing about Classic Haulers, if you ask, they will tell you how well they fit. Have you seen my ongoing post on forming and installing patch panels: https://www.ford-trucks.com/forums/1...g-try-2-a.html

 

Axracer, Yes, I have been following your patch panel thread. And like a lot of other people am finding it very interesting and informative, and am waiting for the next post.
mustangmike6996, Sorry but I don't have any pic's as yet. truck is buried under junk at the moment as its too cold (-27 this morning!) to do anything for the foreseeable future. The panel in question is the passenger side and there is rust damage from the bottom up to and including around the heater vent knock-outs. I've seen some panels for sale which are only about 10 inches or so high, but to do the job they need to be about twice that. Possibly I'll get a panel from Classic Haulers and use Axracers info to make the rest.....when its warmer! Wish me luck!

 

I completely understand.. I tried to do some garage work this week abd t was too cold. I pulled into the proving grounds today and it was -29

 

What if you could have a factory piece that's solid and as high as you'd want it to be? Interested?

 

Tiger, Is this the area? (ignore the slice of fender and windlace attached to cowl, this was done for the flip front)


This is all basically flat metal with straight bends, and is almost all hidden by fender after assembly, so would be easily reproduced in the home shop. Once it warms up, buy a roll of masking tape, 3 or 4 sheets of posterboard (lightweight card stock available wherever children's school supplies are sold: drug stores, walmart, grocery stores, etc) and a package of rare earth button magnets (small strong magnetic discs about the size of a large watch battery. Come in different sizes I like the ~ 3/8" diameter ones. I get mine in a pack of 10 at Harbor Freight, Rare Earth Magnets - Rare Earth Magnet Set, 10 Piece but you may be able to find them at a large crafts store or on ebay) Use the magnets to stick a piece of posterboard to the area to trace it and cut up the posterboard to match the various sections and tape together along the bends until it matches the panel exactly. Don't be afraid to rework and/or remake the pieces as necessary, posterboard is cheap! When you are satisfied with your pattern, cut the taped seams open as necessary so the pattern will lay flat in as few pieces as reasonable. I'd probably do this patch in 3 pieces. Cut the pieces out of your sheet metal (I like to use 19ga deep drawing also called aluminum killed cold rolled steel, but 18ga regular cold rolled will work and may be easier to find, ask if you need online sources.) and using the techniques in my MIG welding tutorial https://www.ford-trucks.com/forums/1...-practice.html to weld them together.

 

Or I'd take Wayne's offer!

 

Axracer, yes that's the panel. Most of mine is rotted/perforated from the bottom to about the paint chip above the knock-outs, in the picture.
I will send Wayne (52Merc) an E-mail and see what develops. Thanks for your help and suggestions.

 

Merc52..PM sent.

 

Let me know if you need help. You will possibly find some understructure behind that area that will need attending to as well once you cut it open. I'm going over to Gary's today and will try to get some time to look at that area on his cab.

 

Axreacer,
There is a small hole that I can see, only looks to be about 2x2 though.
When I get it cut open all will be revealed! No doubt I will be in touch.
Thanks for your help and advice so far........and for the patch panel series!
Geoff.

 

Geoff,
I looked at Gary's cab yesterday. There is no structure behind that panel that I could see other than the door post and firewall/floor. The edge along the door is just a simple right angle bend flange tacked to the door post. Do you have your door off?
I also looked at his copy of the Classic Haulers catalog. The repair panel they sell is just the face portion, and IIRC it was 16" tall, for 100.00. The panel does have a shallow compound curve to it, which might be a little tricky to duplicate if you don't have any metal forming experience. I'd make that panel myself, but you might want to buy the patch if it is tall enough or use a section from a donor cab if that is what Wayne has.
If you don't have a print copy of the Classic Haulers catalog, give them a call tomorrow and request one, it's free and has a wealth of info besides just parts in it making it a must have. Home - Classic Haulers F-1 Parts

 

Axracer,
There is a small hole behind that panel, near the bottom. Feels like another small knock out 'bout the size of a nickel/quarter, now rusted slightly larger. When it warms up considerably I will look into it further. I have sent Wayne (Merc52) a pm and will see what eventuates. I do now have a copy of Classic Haulers catalogue. Thanks again.
Geoff.