How to make custom patch panels with ease.

Here I am back again showing our little tech tip I'm going to show you how to make all that they're all this section here I make it look like it's original state okay I'm gonna start off first by setting showing you this piece that I got this is an original corner panel snake so it was a piece that was replaced on the Kairos little corner for none it wasn't properly installed and it was major issue with caps I had to readjust the gaps up here widen them all this corners were nowhere near where they should be this panel was just body going here was not even lined up the body going was somewhere up around here so I had condyle I had to extend the bottom the floor panel down so I can get this piece to fit properly so I had to trim off all this here so all those recluse the outer skin section so I have nothing for inside the door well as you can see all this in here is gone so I gotta make this off now you would probably want to make up a little template try to figure so the agrees law is this gotta clean and it's gotta come straight out as curved this way and is also curved this way so it's a bit of a tangle of a piece to make this process works the same on do around windows and stuff like that as well on the back window if you're having rusty back windows then usually a lobotomist I sell this little process that I'm doing here now is what's the same thing abuse and a dozen different places on the carrier but I'm gonna show you here on the inside dorage so all I got dollars I got this piece of metal here just cut it off just trim it up enough so defeat there just slide it in the air like so it's it's bigger than what it is it should be this is trimmed up it sticks in farther here it goes in past it it sticks out past it here right all I'm concerned about right now is getting this plane and this plane the same so the sural flow from one to the other I'm not concerned about the waste each or anything inside or like that so all I'm going to do is I'm going to clean up this piece of metal here and then I'm gonna come back and I'm gonna tack welded place here and I'll show you the next step after that ya hair a quick little look at this what I got done because you can see up here the lines up on the flaws on sticks in past spot weld it on again it's never ever pretty you can see where it all hangs out and the bottom and everything is going along there I just got tack welder from the outside then when he calls the door I can look in and I'm happy with my gap and everything that's gonna be there that'll be that'll be the door gap then when it's done right so now what I'm going to do I'm gonna set up for this piece here now so I'm gonna set up here now and start making the piece that will fit in here okay all I have just took a piece of chain it's a little bit longer I want some longer this way because gonna falls down it's going to get shorter on this in here so I'll hopefully this piece here work I'm pretty good but you can see roughly how long it is oneis from this point to this point here so all I'm gonna do now is just rough it in to get a start at the shape hood you can see the way it's going to have the go like that so I'm going to caulk to an MRI test fit it again if you can see them get a little bit closer so now I can turn around in the play around America a little bit more and just set it up here like so to follow that plane that looks pretty good there I'll cut that off there don't see definitely look at that put the it boss I'm gonna go fine tune that prep it all up as you can see now you start to come closer to us in here because I want this to come straight up this way here and straight up this way but I'm not getting over any fuss of it because this girl had to be on an angle like this anyway so I'm gonna dress this up a bit more and clean them up and get a nice fit and clean up this piece of metal and we'll go from there all right so there's the piece that got made up all I did is I just kept cutting it away and then I took a blinder sit for a little grinder like this here they just grow in a th so I get the fit proper the whole point and there I got my feet it's pretty good back here on this corner I trimmed out this corner here so it's sitting underneath the corner so I got at least tighter fit I'm not worried about from this access up here again I've done this before another videos that's something the whole lines we now see so I can sit this off I took America America so long here so I get an idea of where my gap is too and what I'm gonna do is I'm gonna tack weld a great on there now I'm happy was too there you have us at that tackle in place doesn't look like much that's pretty rough-looking but the other concern about is getting your force and this out here tack welded in place so you know you get your plane's right this plane is right this plane is right this playing this right all this here you can work with that and grind it all off the dress stuff so we're going to do now I know as you can see I have the spot weld in place now that I got an oil field where I wants to I'm gonna take this off bring it over the bench I'm gonna start welding it all up and okay quick little break I'm going to show you simple the tools that I use to basically do all I met a fabrication what you see there on the bench is what I basically make everything out of I got no fancy tin snips of you I have a drawer phone I haven't use them in years I use them for small things every now and again we'll also see I use them for cutting off these wheels that's what I use them for but for most precious wood hammer dolly would be Dali go Dali is not around but anyway I could hammer dolly mostly I don't use the dolly a lot because it's mostly just fits of in Chippewa marker Brian clean the pages and clean off the metal cotton wheel like good good grinding wheel with a stone honest and a die grinder friends haulage it's just the extent of making any panels I've gotten into iPhone with the grinders it's so much faster I got two of mine to go for a similar fact you don't have to change these over this one's modified the guard I don't believe and you gotta have a guard on everything this guards were modified to made bigger and it's clock back so you got more distance on us but still you've got the protection against your hands because if these books blowed I can tell you they are nasty if they explode so but and just by cutting them back as they usually go straight across this way on the guards and all I do is I just cut back the guard right here just so you got more area to cut with as you can see right but you still have the protection of your hand because when that explodes at the last place butyl wants that is in the in the internet knuckle there under that hand any workers you're usually holding the grind or like salt so if that explodes it's pretty bad I see so many people you and these grinders caught wheels without a guard scary ok back to the project you know what would you call that right in-home moderate have your head wouldn't she does ease that's basically all I got done is to three pieces of metal welded together the three planes ordered this plane is here this plane is here this plane is here there's nothing pretty I'll weld it all up and I'll grind away what I don't need and there's one little trick I'm going to do some people just came up well in this out here on the outer edge but you know I always like having this edge out here I'll show you later really nice and clean so it looks original and I'll explain why I'll get into that later what I am doing is I ends up welding this entire backside here inside as well so then I got a bit of build here so now when I go to throw us off this outer age it looks it looks original and you haven't got to worry about all right I'm gonna weld all this up clean it all up and I'll be back it's all welded off on the inside here is all welded this outer edge again nothing pretty inside as well as well.i finds when you're making these panels up is best to well inside now it's a lot easier and like I hadn't really but if you notice tonight I'm doing this off the car I find so anytime like you try to do this on the car can turn into a nightmare and if you've got pieces like this that you got to add to the car make three or four pieces in the warm it's best to do it in a panel even if you've got to cut the piece out of the car to do the repairs or make up a new piece where act where I got a cut along that before I took the panel off quick tricks if you notice that each panel is a little bit longer than the one we for this one here I find that if you have bottom the same length trying to well this corner becomes a tangle alley if you're welling it you can wander off into the next piece which will bring up this edge flush just simply works as you can see it got it on here you could wander off and there that one here for the welding right you just you know never be concerned about having a perfect fit as long as you got your shapes and everything there you're going perfect later on so what I'm gonna do now is I'm gonna dress this off one of the advantages of doing this weld in here now is that I can grind every bit of this off now and make it all nice and smooth roll that edge just like a factory lift edge you wouldn't be able to do that if you just welded on the outside of the car you could do it well you'll have chances of this splitting and cracking again but where you got it welded on the inside now as well there's lots of print there for to give yourself a nice dress stage so I'm gonna dress up all these edges and everything here now trim this up so it all fits and caught up that piece on the inside and I'll show you what it looks like remember that tab of metal that I left on this here well number a good reason why you can keep notice now it's least a solid on the bench I'm not going to damage my pieces running in here because this is all excess out here so now I've got secured on a bench so I can grind all this off so just having these big old tabs on there's lots of uses for them and there you have it just a piece made up and they so leg that you can see this rolled edge now is nice and round and smooth it's looks the part almost looks like a stabbed piece right but then when you flip it over it's made out of three pieces I've used this technique for a lot of years doing a lot of rust repair you kind of got a tendency to sort of dream up ideas and figure out things I'll show you here I've done it many times I'll back windows apparent want to show you here on the front window this car here right here this section here I've often had cars all this hair had begun I'd use the same process I'd make this piece up I'd make this piece up as I make this piece up and a weld it all together fit it and you end up having you probably be trying to patch something together and you have an edge here when you go to do filler work or an edge work down here and be so hard to get this to look right but doing this process and then doing a nice job on your edges here which is in this case here is this section here when it come time to well in these corners and doing filler work you will be left with a high spot here trying to to get it to fit and you end up grinding it down and what ended up happening your grind through it you have a whole dare and might not possible it's a nice little quick simple little setup it works great I'm gonna go install this now and we'll go from there there you have a rough test this right now fits in there pretty good you can see we're close I put on the top edge down underneath here push your nut and you can see they seem by your line lines up just a matter and I'll spit just clip this across here let's see what inside here the same thing along here trim too solemn wellness and solace there you have us all but weld in place get corner nature's right nice it flows into this panel here and this flows down to the bottom this here is all the buck welded into the inner structure spot welded in underneath and along the edge here in the wheel well all there seems looks good up along dear splosh this way flush this way it's a really cool process I hope you like that one oh there you go that's another tech tip done and over with it's a great little tactic you ever told CAD cores I pick up trucks like I say in earlier around Windows a lot of early GM cars sixties cars the back windows the lower valance underneath the back when they used to rot out of them I've repaired a number of them and using that process the CAD pours the same thing being a body in 30 years you canö when you'll be applying filler hated these cornered ages that someone had put on them vulgar it up on stuff and I just naturally figured you know let's see if we can figure out a way to make these corner ages nicer so that's what I come up with and I hope you enjoyed us and until the next one

Channel: Fitzee's Fabrications

Views: 382,270

Rating: 4.9387155 out of 5

Keywords: Bodywork, metalwork, rust repair, patch

Id: 1AiDqIHP5Po

Length: 15min 3sec (903 seconds)

Published: Fri Feb 01 2019