Got a 2004 F-350 CC 4x4 that's pretty spotless, but doing some nuisance paint repairs on it. Found a hole at the front lower wheelwell corner on the left rear. Need to replace about a 4x8" section. Thinking about cutting the piece from a complete lower section, flanging, and using panel bond. All proper prep and finishing, of course.

Any thoughts? Should I be having it welded instead? Buy a cheap wire welder and do it myself?

 

RudyF6. I'm interested in your repair procedure. I'm an aircraft mechanic and we see alot of panels "bonded" together on aircraft.

I've got a near spotless '02 Ranger Edge that was "lightly" rear ended. The "typical" damage to pickup trucks when the rear bumper gets "pushed" into the lower area of the corner of the bed.

I found that lower corner panels are aftermarketed in which that area of the existing full side panel is cut off and the replacement "insert" is attached.

I dont need the entire OEM area replaced... just the corner area.

1st off... Im NOT real gung-ho about WELDING a panel on and then grinding and smoothing a weld and then finishing this type of "attachment.

Here's my idea. On aircraft when we need to "mate" 2 panels together without lapping one over the other we do what is called "joggling" the edge on one of the panels...maybe 3/4" or so. Then the mating panel is layed onto the slightly "joggled" area and the 2 panels are attached...usually with rivets. This results in the 2 panels being one flat surface (but you do have a visible joint).

My thought is to us one of the high-tech slightly flexible adhesives to bonded the 2 panels together.... no rivets... no welding.

And if the day comes when that area gets banged up again I can "unbond' the 2 panels and replace the damaged piece. You could even prefinish the part to match the truck color. You would have a joint BUT alot of cars have joints in the body panels.

I would think you could do likewise.

If your interested in hashing over this idea. We could e-mail each other with some ideas.

ptf18

 

I might try quick and dirty first. I cut out the rust today and here's what I have.

Just for the heck of it, I beat out this panel from some hardware store sheet metal.

I may just use some permatex metal epoxy I have and bodywork it. Filler will only be the thickness of the body metal. Yes my patch fits well! I'm just playing to see if I can make it look decent since I've never done it before.

I may end up back to plan A if it looks bad.......

 

BTW, even if it doesn't look so great, I am spraying clear bedliner over the lower body and around wheel wells after paint. That texture may hide some ugly! Also have OE style flares going on and they will cover at least half of the metal repair area.

 

Nice. Hope it lasts for the time you own the truck.

 

So I made the patch fit so we'll it laid perfectly in place without clamps. Trimmed it to overlap an inch and went ahead with the epoxy job.

Here's inside after priming

Finished and painted. Paint was not available in aerosol, but a Carquest store not too far from me mixes and fills aerosol cans while you wait. A bit dark, but hopefully it will blend a bit when I wet sand and polish.


Next step: see that spring? The whole frame and undercarriage looks like that. And I've already started cleaning up the worst of it....

 

I'm glad you're happy with it!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!