This is great info.! Thank you for sharing it with me. I really appreciate it.Hi Nick
so here goes,
For the gap I used short strand fiber glass, let dry then ground down flat, after that I used bondo to get it perfect.
When your actually putting the panel on you need something to glue to, so i fished a plate behind so that I had a lip that I could glue to if that makes sense.
This is where the clecos came in, No matter how exact you are you are going to have a gap between the existing panel and your glues on patch. I think using my pictures as reference this process should make sense.
personally I tack welded along the bottom of the panel but maybe its possible to use the adhesive.
Yes, the plates that you worked up make very good sense. That's just the sort of ingenuity that I need to get my truck sorted out.
I'm going to borrow my neighbor's welder and go pick up a couple of crappy panels from the junkyard for some practice. Going the tack-weld route sounds like the way to go, and I'm guessing, with a little practice, I could manage that without botching things up two much. My fear with taking the all-welding approach is that I would blow through and warp my new and existing panels.
Thanks again for the info. and the inspiration.
Take it easy.