Patch Panel Installation?

[JRB]

Do you cut the existing floorboard out and cut to fit exactly or do you leave a slight amount of the old floorboard (Still in good condition,Not rusted) and set the new panel over it and weld? Could you give me some Ideas how you did yours?
Thanks,
JRB

[BobbyK]

Most try and leave as much of the orig. metal intact as possible.Cutting back only as far as needed to get to solid metal.
Then trim the replacement piece to fit.

[krue]

I suggest getting ebfabman's video, goes in depth in patch panel fitment.

[JRB]

BobbyK
Do you leave any overlap when you cut the panel or do you cut to exact fit. I have a crimping or what you would call a flang pnumatic tool. If I flang the old metal the new panel would set in the flang lip. I am new at this fab stuff so I am trying to make my way through this as painless as possible.
Thanks,
JRB

[northcountry67]

I use a crimping tool to crimp the edges of the new panel so that it will ovelap the old panel from the bottom and still be flush with the old panel level. Fill the small gap with weld and finish with fiberglass filler over the weld before plastic filler. Always spray the panels with a weld through primer before welding.

[stllookn]

My personal preference is to remove (disturb) as little as possible. I try to cut out only the rusty metal and use smaller patch panels since it will minimize the amount of welding and adjustments I have to do. Even if I use only 1/8 of a patch panel it is cheaper, easier and faster than hammering a new part out of flat stock. Board member Rockcrln or ebfabman may not agree but they are artists...I'm just an old metal butcher...LOL!

[JRB]

Never thought about cutting that new 40 dollar panel in half. I do see the sence in it though. Its mainly the couple of inches next to and up the kick panel and around the lower post.
NorthCountry67 do you also weld the bottom where the lip is under the existing old metal?
JRB

[Rollie396]

I'd really suggest a butt fitup.Lap welds leave the area between vunerable to rust.Not only that,butt joints have a much cleaner look and are worth the extra effort.
I do agree with leaving as much original metal as possible and also with the suggestion of ebfabman's vids.He repairs a cab before your eyes and describes everything as he goes.They really help boost confidence in a project like this!

[Botietruck]

Rollie396 is right on. Butt weld results are much better than lap welding with little chance for rust to have a place to start. Replace as little of the original metal as possible and when welding take it nice & slowwwwwww. Patience is a virtue! Good luck and don't forget to take & share some pictures along the way.

[Rokcrln]

Yes butt weld in the new panel is the best but keep in mind you are getting rid of rust so it is better lapping the new panel then leaving active rust on you project. Lapping is alot easier for new guys and it works great as long as you weld prime all affected metals before welding then once you are finished use a good factory seal sealer (not bondo for this app.) on both sides of your floor board patch. Good luck. If you have any quastions let me know.

Kevin

[Stroker]

JRB, Do you have a way to post a pic of your floor pan? If so you could problably get a more specific answer to your question. I'de agree with the others that but joints are the best choice in most cases. But the fit up is much more critical. When I repalced mine I made some of the joints in locations where there was some sub structure underneath the floor pan to act as a backing and butted the pactch panel.

[JRB]

I will take some pictures of the floor pan and the patch panel and put them on this string.
JRB
Thanks for all the support on the questions regarding this Patch panel installation.

[JRB]

Here are the pictures of the Floor pan patch panel and the Kick Panel patch. I also took pictures of the existing holes in the floor.
Thanks again for all the help and suggestions.
JRB

[Stroker]

That looks very simular to what I had? First, I would also suggest the ebfabman's videos, they will take you step by step thru the repairs you will need to make. If a picture is worth a thousand words then 4 hour worth of video must be priceless. Here's a pic of how I cut my floor pan. The cut is centered over sub structural brace that runs between the cab mount areas. Sorry I don't know what it is actually called. Included a pic of my patch panel for the toe board floor area, used some of the left over patch panel to fab.

[Stroker]

I must be getting to old. Here's the Pics.

[Stroker]

Notice I had a couple other pics that might help.