Patch panel help

[driver]

I have a Sonoma p/u that needs a cab corner. The panel extends to above the creased style line. Where is the best place to put the weld seam? In the crease, lower on the convex part, or lower still on the flat part of the panel. Thanks in advance.

 

[MP&C]

My first objective in looking at a patch like this is to open up the interior panel and pick the area that allows for clearance from the back side for using hammer and dolly for planishing the weld.

Secondary to that, you want to choose panel features that will work in your favor. Lower on the panel is more of a flat or low crown, which has a tendency to lose it's shape more quickly given exposure to the heat from welding. A higher crown area of the panel is a better choice, as it will help to hold the panel's shape.. Looking at the crease, it's been my experience that not all reproduction replacements are all that accurate, especially when it comes to those creases. Given all those considerations, and providing the access from the rear permits use of a dolly, I would make the cut line as shown below..

If you haven't already seen this thread, it will help out with some of the other details I may have missed..


Welding in Patch Panels



.

 

[Kevin54]

I bought my panel for my fullsize from LMC. When i welded the replacement panels in, I went to the height of the replacement itself. I don't know how an S10 is made as far as behind the corner, but on a fullsize, there is a shelf in behind. When I made my marks and cut mine out, it left that shelf exposed. Once you open things up, you will probably find a lot of foam sealer. That should be all cleaned out as good as you can get it, then us POR15, or instead of that, use Chassis Saver (same thing but cheaper)

The foam sealer is the Generals way of making things quiet, all the while collecting moisture and rusting things from the inside, out.

 

[driver]

Robert;
Thank you for the tip.

Kevin;
I found the shelf which appears to be slightly below the line suggested. If I put the weld seam on the shelf it should keep warpage to a minimum.

Thank again.