Cutting sheet metal panel
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Lead Driver
Joined: Aug 2003
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From: Boulder Creek, Ca
Cutting sheet metal panel
May be exceding the alloted number of post regarding present project. Going to start cutting out floor pans, as a novice perhaps overly concerned about making precise cuts. Fear replacement will fall thru the hole and then be face will filling in gaps. Ideally, plasma cutter would be the solution but can't find tool shop who rents them, and too costly to purchase for limited use. Thought about purchasing a 'nibbler' or 'shear' ; if so, would nibbler be more precise than the shear. I have a die grinder, air file, and air chisel and thought I would check to see if anyone has an opinion.
dave
dave
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I've used just about everything you can think of from nibblers to shears to die grinders to plasma cutters. If you're worried about cutting too much, just take a few measurements off the new pan and if need be, leave yourself a bit of an overlap, it's not going to hurt anything in the long run to have a small one ( 1/4 - 1/2 " )
The main key is to just take yourtime. Measure twice, cut once, and if you do happen to cut a lil more than you plan, you have the old pans you can cut small patches out of if need be..
The main key is to just take yourtime. Measure twice, cut once, and if you do happen to cut a lil more than you plan, you have the old pans you can cut small patches out of if need be..
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Lead Driver
Joined: Aug 2003
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From: Boulder Creek, Ca
Sounds like best to cut long and then make final adjustments. Original pans are 20 gage, looking at couple supplier's, 1 pan is 20 gage and the other 19 gage. Incline to prefer going w/ heavier 19 gage pan but not sure whether difference in thickness would present problem for a novice welder, any suggestions. Again, appreciate the help.
dave
dave
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It's not that big a difference when it comes to the welding,, you'll be fine, just practice on a few scrap pieces first to get your feel,, and make sure to clean the cut areas with a wire wheel first so you get good penetration on your welds.
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From: western montana
I take a air body/sheet metal saw that works really well- but you have to have 2" clearance behind the metal- works awesome when you can use it. I also take scrap panels and make cuts in them to practice butt welding.
I've been considering cutting a patch panel just a bit bigger than the area- tack weld the patch over the bad spot, mark the cut, drill a start hole inside the bad spot, then using the saw to cut both the patch and the bad spot out at the same time- grind off the welds and wala- should have a perfectly matched set. I have a good month before i can start my next car so it will have to wait. Remember that the welds do not have to be perfect and you can screw up and make it right. A good grinder with a fresh pad is a must imo.
I've been considering cutting a patch panel just a bit bigger than the area- tack weld the patch over the bad spot, mark the cut, drill a start hole inside the bad spot, then using the saw to cut both the patch and the bad spot out at the same time- grind off the welds and wala- should have a perfectly matched set. I have a good month before i can start my next car so it will have to wait. Remember that the welds do not have to be perfect and you can screw up and make it right. A good grinder with a fresh pad is a must imo.
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Lead Driver
Joined: Aug 2003
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From: Boulder Creek, Ca
Thanks for suggestions, i have since purchased an air shear saw and now have full complement of tools that should accomplish the job. Floor pans should be arriving soon. Really like the idea on tacking replace'mt panel and cutting both at same time. The pans should be arriving next day or so, ordered full panel for each side, may be able to give the suggestion a try.
dave
dave
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From: western montana
I've used the air cutting wheel thingy and the air jig saw type- want to get a nibler as well. cutting wheel works fait to ok but turns are difficult, body jig saw type is awesome, fast, thin cuts but needs the clearance- nib is great too. Also had to fire up the torch at times when messy isn't a problem
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Lead Driver
Joined: Aug 2003
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From: Boulder Creek, Ca
Since posting question, came across book at library 'pro paint and body' where author describes basic patch panel repair and indicated there are number of tools used to cut out the old panels but prefers the 'double cut power shear', "they give you a nice clean line, and don't warp the metal". Not sure, believe they come in single and double blade, I purchased an inexpensive double cut air type, they also make electric but believe the air are cheaper.
dave
dave