Patch panel fab or buy decision

robking

Promoted Users
Hi folks, looking for some wisdom from the many knowledgeable fabricators here. Any advice is greatly appreciated.

The tail panel on my 68 Dodge Coronet (one year only) has a lot of patchy rust damage across the bottom. Note that all the damage on mine is actually hidden by the bumper, so if a repair job isn't exactly perfect no one will know and I certainly won't mind.

my_tail_panel.jpg


For the low, low price of over $600 I can buy a 69 tail panel from AMD, and use the bottom half (that much is identical) to fix mine.

Full disclosure, not my idea, came from Motortrend.


69_tail_panel.jpg


Most of the damage on my panel I could pretty easily repair (single bend) however there are a couple of areas like this one that form a "pocket" for structural strength that seem like they are going to be time consuming and aggravating to fabricate.

PXL_20220316_160121957.jpg


The only way I could come up with to fabricate these areas would be with a sheet metal brake to form the valley, then fold the bottom over and weld the corners closed (hope that makes sense). Would it be possible to create a hard wood form and hammer something like this?

I feel like I know the answer here (suck it up and spend the $600) but thought I would put it out here to see if there's a straight forward way to salvage what I have. I will say the idea of cobbling together 10 little patches isn't very appealing either (the article above shows what that could end up like).

Every dollar spent here comes out of budget for other goodies, but at the same time I'm starting to want to drive it more than I am wanting to work on it. :) I'd really like to shoot a coat of SPI epoxy on it and drive it this summer if at all possible.

Thanks again for your time,
Robbie
 
How solid is that panel? If it is solid but for those spots the then patching those spots would be doable.
What is your skill level? What equipment do you have?
 
In his DVD set Peter Tommasini show techniques using hand tools to replicate those bulged areas. His DVD set would be a good place to start learning if you are interested in Metalshaping.


If you are getting tired of working on it and want to drive it, the quiclest best result would be to bite the bullet and buy the panel section and MIG weld it in. If you are wanting to save that money you can try patching it. Making small patches and MIG welding them in would be doable.
Trying to make that panel with no experience, it will not turn out like you hope.
 
Keep in mind to the higher the quality repair done will not hurt the value of the car. The more of a bodge job done will. Important to consider these days with the value of that car and in old cars in general.
 
In his DVD set Peter Tommasini show techniques using hand tools to replicate those bulged areas. His DVD set would be a good place to start learning if you are interested in Metalshaping.


If you are getting tired of working on it and want to drive it, the quiclest best result would be to bite the bullet and buy the panel section and MIG weld it in. If you are wanting to save that money you can try patching it. Making small patches and MIG welding them in would be doable.
Trying to make that panel with no experience, it will not turn out like you hope.

I do think it's repairable, and before AMD got the 69 tail panels back in stock that was really my only option.

I used to work in an HVAC sheet metal shop, and could layout square to round offset transitions, so I think I can layout and use the brake I have to form those valley sections without too much trouble (other things I've fab'd up I formed up using aluminum flashing as a prototype before jumping to the sheet metal). I really would love to learn more about metal shaping but I absolutely don't have the tools or experience there.

I may try fabbing the valley piece up one evening and see how it goes.
 
Keep in mind to the higher the quality repair done will not hurt the value of the car. The more of a bodge job done will. Important to consider these days with the value of that car and in old cars in general.
Agreed, that's why it's taken so long just to get to this point. I have a hard time deciding what's "good enough" so usually slog through trying to learn and do it correctly. Happy so far but I'm not getting any younger. :)
 
If you are trying to duplicate the factory panel, You're not going to form those valley sections correctly with a brake. It is a compound type curve in those areas. You could form them with a blocking hammer, sandbag and dolly, but a brake will not duplicate that valley section correctly.
 
The only way I would know how to make that panel would be to first make a paper pattern of the panel. Highlight all the info on the panel on the paper pattern. (trace) then transfer all the info to the metal blank. Probably would do the bends on a brake first then block the various depressions in with a blocking hammer and sandbag and refine them using various dollies. It would take a while.

Those areas need to stretch which is something that a brake can't do.
 
You could also bend the panel with the brake, but make those depression areas separately from the panel, then cut out a section and weld them in the panel. Depending on how bad the lower part of the panel is, I would probably make the patches and weld them in the original panel. Much safer though to make a replacement before damaging the original.
 
Last edited:
Chris
Can I get a pic of the “sandbag” you referred to and how do you use it? A short explanation is fine.
Thanks
Dave
 
Chris
Can I get a pic of the “sandbag” you referred to and how do you use it? A short explanation is fine.
Thanks
Dave

Three different sized ones.
img04_big.jpg


A very basic explanation is you use them to stretch sheet metal with a blocking hammer in order to put shape into it. Then the metal is planished to smooth and refine the lumps.

Link to bag for sale at Dagger Tools
 
Three different sized ones.
img04_big.jpg


A very basic explanation is you use them to stretch sheet metal with a blocking hammer in order to put shape into it. Then the metal is planished to smooth and refine the lumps.

Link to bag for sale at Dagger Tools
FWIW, I've stumbled on threads where people talk about going to thrift shops and picking up sturdy leather handbags, etc and using those to make their own.
 
Chris
Thanks - you got me started and now I was able to watch a total amateur video of one being used. I get the idea clearly but will hopefully but have to use it much if at all.
Thanks again
Dave
 
Chris
Thanks - you got me started and now I was able to watch a total amateur video of one being used. I get the idea clearly but will hopefully but have to use it much if at all.
Thanks again
Dave
Dave (or anyone else) if you are interested in Metalshaping check out some of Peter Tommasini's videos on youtube. He also sell a 10 DVD set that will make you a shaper if you watch them and practice. Peter is an amazing tradesman and a great guy.

 
Back
Top