Front lower fender ROT, any tips?

[boucher racing]

Last night I washed the truck down with my daughters and they had fun shooting water in behind the fender and watching it come out the side. It was funny watching them, but got to thinking that is janky!

So, later that evening I innocently take a flat head screwdriver to poke around a bit... mistake.





The time has come for me to venture into bodywork! Today, I bought some lower patch panels from Top Banana.

Can anybody give me some advice on this job? Tips?

Boucher'

[MusicMan70]

Something saved to pass on

http://www.67-72chevytrucks.com/vboa...d.php?t=551521

[BR3W CITY]

Hahaha, we did the exact same thing on my build; a little boredom and a flathead led to the patches on both sides.

I will say that If you choose to do the patches with the fenders on, at least take the doors off, otherwise you'll constantly run the risk of dinging/cutting/splattering etc on the door panel. Its worth having the ease of access to all sides of the panel and its mounting bolts.
And I say this about ALL sheet metal repairs; if you don't have a welding spoon, buy one. It has saved more sheetmetal and scraps than I can count, burn through is such a beatch.

[tincan1966]

Looks like somebody got charged by the pound for bondo at one time. Most likely took longer to cave it and pave it in plastic than it would have to repair it right.

I am sure your repair will be miles ahead of the previous one.

[61_FL_Apache]

Body and metal work is an art all to itself! I wish I had something to offer..

[Trsmotrhed]

Take your time welding as not to warp the panel and you will do fine.
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[Metalaroundstone]

What did you think of the quality of the Top Banana patch panels. I wonder if they are the same ones sold by LMC and other classic parts distributers. I have heard some complaints about how these parts fit. Let us know.
Thanks

[lil_sahara450r]

Yes! Please give us some feedback on the patch panels!! I will be doing this soon as well

[donthekawguy]

There is a guy who has a youtube video showing a detailed repair of 60-66 fenders.http://youtu.be/oydlEWgNths
Found it.

[tincan1966]

Originally Posted by Metalaroundstone

What did you think of the quality of the Top Banana patch panels. I wonder if they are the same ones sold by LMC and other classic parts distributers. I have heard some complaints about how these parts fit. Let us know.
Thanks

I purchased all my patch panels from Top Banana, and was pleased with the quality and fit. I've tried repeatedly to use the panels LMC sells and mostly disappointed. Of coarse, not like LMC actually makes the panels, either.
There's only a small few suppliers of these panels, just alot of people selling them.

[da_bears_da1]

I got my floor patches from Classic Parts of America and they were bad. One outer floor panel was 3/4" shorter in the front than the back. Have a hood patch from LMC but am a couple of months away from working on the hood. Based on feedback on this site, I will be going with Top Banana in the future. For my bed, I will be using Mar-K.
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[racecougar]

Originally Posted by Metalaroundstone

What did you think of the quality of the Top Banana patch panels. I wonder if they are the same ones sold by LMC and other classic parts distributers. I have heard some complaints about how these parts fit. Let us know.
Thanks

All of the panels I've bought thus far from Top Banana have been Tri-Plus stampings. Unless I'm mistaken, that is the same manufacturer that LMC gets their stampings from. I've been happy with the patch panels that I've bought to date, though everything does require tweaking here and there, as is to be expected. We've actually just discussed this on my build thread.

http://67-72chevytrucks.com/vboard/s...=560434&page=2

[tincan1966]

I apologize, I need to correct myself- I tried a set of complete front fenders from LMC and was very disappointed, but have heard that there aren't really any "good" aftermarket ones.
Been patching as many OEM fenders as I can save.
Got a score the other day from a guy throwing 4 pairs of fenders away because they were rusted- he bought "new ones" LOL!
I put them back, will buy patches and repair a pair every now and then.

[KJSR]

If you flange the panel you can use the panel bonding glue to secure it saving a bunch of work welding and fixing the metal. Makes life much easier.

[boucher racing]

Originally Posted by KJSR

If you flange the panel you can use the panel bonding glue to secure it saving a bunch of work welding and fixing the metal. Makes life much easier.

Please explain. I have no clue about the bodywork arena.
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[BR3W CITY]

Its a much less common way of panel repair. Basically on a square patch, you can "step" the edges, giving you a lip on all sides that tucks UNDER the surrounding metal. People do this and use Fusor or aircraft adhesive to creat a patch panel.
instead of leaving a welded bead, it leaves a "Groove" that gets filled.

[1966shortwide]

boucher racing, i can fix your left fender , simply bolt on new fender ,i have a nos in the cardboard wrapping from general motor part's ( 850.00 ) i'm sure you want economy route, ha ha all good suggestion"s above , good luck.

[Captainfab]

If you don't need the full size of the patch panel, trim it down to a size just big enough to get into good solid metal to weld to. I've seen many guys use the full size patch panel, when they don't need a patch than big. Typically a smaller patch means less overall work involved.

[da_bears_da1]

Originally Posted by Captainfab

If you don't need the full size of the patch panel, trim it down to a size just big enough to get into good solid metal to weld to. I've seen many guys use the full size patch panel, when they don't need a patch than big. Typically a smaller patch means less overall work involved.

As always Capn is right on. I used full patches on my first side of floor repair. Then got the good advice to use as little as possible. Second side was done in half the time and with a lot less aggravation.

[boucher racing]

Originally Posted by Captainfab

If you don't need the full size of the patch panel, trim it down to a size just big enough to get into good solid metal to weld to. I've seen many guys use the full size patch panel, when they don't need a patch than big. Typically a smaller patch means less overall work involved.

Thanks for the tip. I will try to document the process when I get around to it and post it.

[boucher racing]

Update:

Nothing like a car show deadline to motivate my ass! It being the Hot Rod Reunion in Bowling Green, motivated me even more, my favorite show!! Myself and forum member K5 Addiction, rolled up 65N bright and early on Friday. Had an amazing time.

Back to the fenders.... I started to cut just the rotted part out with an arc shape, then tried an obtuse angle, then scratched it all. I cut it parallel with the top of the fender. It seemed to work best for me. It was a bear cat getting everything to line up. Totally true about measure x10, then cut long, and shave it close.

A few tips:
- watch your fingers when hanging a fender, if your door is open. Because if it shuts, it will turn all of your finger nails purple. My daughter asked me if I painted them.
- watch the two youtube videos about this repair, very helpful
- practice with your welder on scrap panels to get the welder setting right. I had a little issue with blowing through on the panels

Pics:
driver side under support, looked really good.



Passenger.


Driver. Previous damage, filled with bondo, prob should have replaced fender.


Almost Finished.



Speaking of... I think the truck is single stage paint. How can I paint the patch panel and feather it in? With not knowing of the paint color.

Boucher'

[Captainfab]

Those repairs look good

Most of the better auto body/paint suppliers have an electronic scan tool that can tell them how to mix paint to closely match your paint.

[Grizz1963]

Very usefull thread this.

Thamks all contributors.

[TJ's Chevy]

Well since I am no body man I was gonna say "Just buy a new fender" but you already have the problem solved!! Nice work!!!! LOL!

[markeb01]

It's also important to fill the top and edges of the inner support brace. As designed by GM it allows tons of crud to pack up in the channel with nothing but a tiny drain hole in the bottom. When enough leaves and debris piles up a compost pile forms inside the inner support with no where to go except bursting through the face of the fender. Unless all of the gaps are blocked preventing debris from entering the inner brace, the repaired fenders are going to repeat the rust out cycle some time in the future.