[Bob66K20]

Originally Posted by Caddylackn

Go into this project with realistic goals. Yes you can do this, but there is a learning curve. Don't expect the first side to come out perfect or be easy. The second side will take about 1/2 as long as the first and will come out better. You may consider redoing the first side after the second side is done. The repair panels are not that pricey. I would only tack weld in the first side, then finish the second side, then finish the first side.

1. Check door gaps regularly with every test fitment before fully welding in the whole panel. Try to leave the doors on since removing it messes up the original adjustments that made it close and latch good. If you have to remove the doors, Consider marking the door hinge bolts first with a mist of primer so you can put the door back on in the exact same spot.

2. Only tack weld everything until fitment is good. Then increase the tack welds until they are only 1/2" apart, then stitch them together. Use a coat hanger for filler material at the end in places where there is over 1/8" gap, instead of just filling it with wire.

3. Don't weld longer than 1" in one weld. It will get the panel too hot and it will distort. Work around the perimeter alternating sides to keep the panel from getting too hot.

4. Minimize welds that are in areas that you can't clean up with a grinder. One tack weld then some seam sealer, then paint, will look way better than a big goober weld painted that you couldn't grind down. This is important around the door jambs where the finished product is painted and it shows.

Realistically, your first repair job is not going to be perfect when done. If you are patient, it will look good at 5' and the doors will close good, and the gaps will not be too noticeable. Expecting show truck results is not entirely realistic. The next truck you do will be better.

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