I bought some patch panels for my 91 ford, and I was curious, is there a proper way to weld these in? My friend at work was telling me to get a crimper to crimp the metal then weld it. I know you have to weld in different areas so the metal doesnt get hot, any other advice?

 

Flanging is one method.

Butt welding them using "Cleco's" as clamps is another.

I did my patch panels without either. What I did was cut the panel slightly oversize, then using my angle grinder, angle the edges on the patch panel. Then angled the original sheet metal I'd be welding it to, the other way, so the angles rest on each other reasonably well. Then clamp, then tack in various places, remove the clamps, and continue to fill in the gaps with your welder. Then grind endlessly!

 

That actually sounds like a good idea, and I remember you poseted your patch panels awhile back and they looked great, I will have to try that.

 

Here's my website if you need more information. http://frederic.midimonkey.com/_index.html

on the left is a menu... click "vehicles", then "F350", then "bed rust" or "bed repair", I forgot what I named it. Up comes the pictorial.

 

I finished my first- got way impatient and used thicker sheet as the patch- it was interesting- in order to penetrate the patch I'd blow through the body- ended up stacking on material and grinding ad-nasea- got it done and it looks ok- down low on body and will be covered with bed liner paint. I have 4 more to do but am waiting to get the right stuff. plan on usig about 1/16" gap and will spend more time getting the piece aligned better as far as depth...fun stuff and, yes, frederic, you are a patch god. I am also taking my time to make sure i kill all the hidden surface rust that i can't get to and grind away- then will use a por type product. also drilling extra drain holes and even ut a place to get to to clean out a hidden place better.

 

The gap will guarrentee burnt, jagged and wildly warped edges. By beveling them having one over the other slightly, the material is "thicker" and less burnthrough.

Edges love to disappear.

 

One thing I have noticed about the patch panels I got, to the ones you have fred, is the ones I have are alot larger, does a guy have to trim these down? Or is it best to trim more out of the box?

 

I trimmed the minimum off the bedside, just to make the welding area (and potential for warpage) as small as possible. The hole I cut was just slightly larger than the rusty area itself. Then I trimmed the panel to fit.

I bought the larger panels, because I hadn't cut into the bed when I ordered them, so I wasn't sure how far up the rust went. Often rusty areas, just as they started to bubble through, are significantly larger than what is bubbling. The original paint hides it well.

 

the best way i found to replace wheel well panels is to use the entire panel .first i put the panel up to the truck and temporary secure it with rivits then i scribe a line the whole way around the panel .then remove it and measure in 1/2 inch from the scribed line and thats where i make the cut . this 1/2inch of metal will give me something to weld to.before welding grinde the panel and bedside well also it is a good idea to cover the inner bed side and panel with undercoating.next use a punch and flange tool to flange the bed side and punch a hole every 2'' on the panel for welding then place the panel on the truck use a rivit on every other hole to hold it securly while welding this way warpage will be minimual. then drill out the rivits and spot weld every remaining hole . next grind welds flush with metal coat entire grinded area with a coat of fiberglass (not tigerhair).then board sand flat area block sand others.then a skim coat of plastic body filler is a good idea to fill in pits and imperfections .block sand then primer with a good urethane filler primer .finally wet sand entire area to be painted with 400grit and prep and paint.