Cutting sheet metal
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From: Santa Clarita
Cutting sheet metal
I'm going to be replacing my inner fenders with my own fabricated fenders. I was thinking about cutting my old fenders to ease taking them out (since they are already hacked up anyways.) Any suggestions on what to use? I've been told a nibbler, or air shears, and even a sawsall. Any experience using these or suggestions what will work best?
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From: Salmon Arm
actually, if no plasma, probably the next cleanest would be an air powered cut off, then some grinding afterwards to remove whatever you cant get with the cutoff wheel. that air nibbler is going to be hard to get in there
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From: Santa Clarita
I don't have a plasma cutter and don't want to spend the cash to get one right now. I don't care about the quality of the cut, because the fenders are coming out anyways. I'm looking for an easy way to cut them out, instead of pulling them out as one piece. I'll probably make one long hortizontal cut along the fender and one vertical cut near the air horns. I think I need a mig welder before I invest in a plasma cutter LOL.... I agree the plasma would be nice.
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From: Riverside, So Cal
Ed -
I use an angle grinder and cutoff wheel for almost all my sheet metal cutting needs. It would be the easiest way to cut yours out.
I would prefer to disassemble the fenders, myself, and remove the inner fenders in one piece. That way, the inner fender makes a nice pattern for the new ones. You will need to know where the attach bolts go and mock up the interface of the front ends to the air dams and the rear ends to the firewall. The lap joint between the inner fender upper edge and the outer fenders is also not a flat bend. It has a slight crowned shape. I think making new inner fenders without a pattern would be really difficult.
If you are reluctant to take it all apart, just drill at least (2) 1/8 dia holes between mating parts at each interface before you disassemble it, then use clecos thru the holes to reassemble. Works like a champ to exactly reproduce the fitup.
I use an angle grinder and cutoff wheel for almost all my sheet metal cutting needs. It would be the easiest way to cut yours out.
I would prefer to disassemble the fenders, myself, and remove the inner fenders in one piece. That way, the inner fender makes a nice pattern for the new ones. You will need to know where the attach bolts go and mock up the interface of the front ends to the air dams and the rear ends to the firewall. The lap joint between the inner fender upper edge and the outer fenders is also not a flat bend. It has a slight crowned shape. I think making new inner fenders without a pattern would be really difficult.
If you are reluctant to take it all apart, just drill at least (2) 1/8 dia holes between mating parts at each interface before you disassemble it, then use clecos thru the holes to reassemble. Works like a champ to exactly reproduce the fitup.
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Joined: Oct 2004
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From: Durham NC
Ed, am I missing something here? You want to cut up the outer fenders to get the inner fenders out? your outer fenders sure look good to me. If you mean you want to cut up the inner fenders to get them out, That really doesn't make much sense since there are only about 10 bolts that hold them in it will take longer to cut them up than to take out the bolts. The outer fenders do not have to come off to remove the inner fenders. I might see cutting off the bolts or nuts with a cut off wheel if they are heavily corroded, but can't quite see cutting up the sheet metal since you'll still have to take out the bolts.
Last edited by AXracer; Dec 22, 2006 at 12:14 PM.
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From: Santa Clarita
I hear what your saying guys, this is my problem. The previous owner had a tilt front end on my truck and then changed to a original front end, thus the inner fenders are cut out with a gas torch for the tilt. For some reason, they welded the outer fenders to what looks like the cab? It really needs to be unwelded and probably new outer fenders put on correctly but my truck's paint is in good condition and I don't want a new paint job. This is why I'm trying to remove these inner fenders without removing the outers and fabricating some inner fenders from 18GA. Anyone who wants the inner fenders on the truck is more than welcome for patches, etc. Let me know. I know it has a crown shape to it so I'll be making the inner fenders two piece and fabricating some type of plate that will cover the airhorn area/ radiator. If it doesn't come out right, I may have to redo the whole front end. I'll post pics when I get to that point.
Hotshot
Joined: Oct 2004
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From: Durham NC
My inners were cut the same way, it just makes taking out the inners that much easier. They bolt along the hood groove, and to the front wind deflectors, and to the lower firewall (which is the part they probably cut away) There is no need to take off the outer fenders.
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From: Santa Clarita
AX, your correct, I tried to download a pic but it's not going through. I'll try to unbolt the inner fenders and remove them. I noticed the PO even welded the front air horn portion of the inner fender to the air horn. Can you say, STUPID..? I'll have to use a grinder and take that off. Thanks guys.
Last edited by imlowr2; Dec 22, 2006 at 12:43 PM.