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The front of my bed is pushed in and should be replaced. A close friend told me to have a piece of metal plate cut to fit the front bed and simply mount it over the bent up wall. Anyone try this with their truck and how did you mount the new metal liner? I know a new one cost about $150. My problems is I have to repaint it and install it. Trying to look for an easier way...
I had a local sheet metal shop (HVAC ductwork, etc) bend me up some 16 ga. angles, and they were able to do large sheets. I'd bet any similar shop could take a large sheet and bend the upper edge into the same configuration as the stock piece and for a lot less than $150, so you could outright replace the front panel. I was very pleased with the work, these kinds of shops do tons of custom work every day.
I think it'd be tough to weld in a cover without making it warp or distort.
I had the L-shaped piece at the the top front bent in a metal shop. Put it over the top of the original piece and migged it from behind and below. I had to trim each end on a 45 where it meets the side of the bed (flareside). The only difference is that the bend is slightly rounder than the original but is not noticeable. Another slight problem was that the sheet metal (hot dipped steel?) I used had a coating on it. It took a lot of sanding with 80 grit on d.a. sander to get it off. Need to find a shop that has automotive type sheet metal.
Jim
Consider using a piece of 3/16" thick, bright finished, aluminum diamond (tread) plate. After straightening the original front bed bulkhead panel, I bolted this diamond plate in with stainless steel hardware. Any metal shop can easily shear a piece to your required dimensions. Looks great, required no painting or metal work, and won't rust.