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| This is what I'm starting with. Rust to the point of holes. The facia plate has been removed and it is salvagable. The other side (left) of the deck is in better condition, even though there is some rust in that area, too. Next step, find some poster board and make a template for the repair. |
| The template has been marked and cut to fit. Basically you place the poster board over the area and attach it as best you can to the shape of the area. Then start making marks where cuts should be. This took me two times to get to this point. It does take some practice, so don't get frustrated. Besides, the poster board is cheaper than the metal you're going to cut Trial fit the template to make sure it will work in the area to be repaired. |
| Once you are sure you have the template cut out correctly, then lay it flat on the sheet metal and transfer it. When you are done, start cutting. If you look closely, you'll see I also made marks where the metal will have bends. This will help locate these bends when you start forming the shape of the repair piece. The sheet metal I'm using is from a non-used floor panel, so it will be more than thick enough. A small MIG welder for thin gauge sheet metal will also come in handy. I bought mine at Harbor Freight for less than $200 and I can weld up to 1/4" steel. Once the piece is cut out, you can start bending it into the shape you need. This may take some time if you don't have access to a metal press. I didn't, so I stuck it in a vice between 2 pieces of angle iron to help form the creases I'd need. |
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| I started the bends by hand, then used a hammer to sharpen the radius of each bend. If you have too great of a radius, it will not fit correctly. But you also don't want too tight of a bend, because you run the risk of tearing the metal. Take your time and work the metal slowly. Also, after each bend you make, trial fit the piece to make sure you are on the right track. No sense in wasting your time if a bend is made incorrectly and not noticed until the end. Click on the picture below and you'll be able to see where I had to re-bend a few areas. |
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