Back to replacing rusty stock parts on the panel truck. So the rear valance and the lower portion of the rear tub was rusted through. The closeout under the valence between the rear bumper and body was also toasted and needed to be discarded. Someone had scabbed on some fiberglass repairs on the outboard portion of this closeout so it was removed and trashed. Later I hammer-formed a new one on a wooden buck. I then cutout all the rusted areas on the aft end until I got to decent metal and treated the rusted substructure as required.
Once I had all the corroded metal removed then it was time to start adding back good metal. I had ordered replacement rear lower tub patch panels for both sides so I repaired some of the under structure that was rusted out since it was open and accessible with flat metal that I formed and then I welded in the replacement outer panels. Then I moved to the under door structure rework.
The center support for the bumper to body closeout (what I call a hat section) was rusted on the aft end so I cut it off and formed a new section to weld into the removed area. I also had to fab the outer most supports that bolt to the tub since the existing ones were too far gone but good enough for making a pattern. They were simple brake-formed sheet parts. I purchased the repair panel for the under door threshold (two-piece) and welded it into place. I then had to fab the drop portion (the vertical portion) on this panel. I again created a wood buck to help with forming these parts. If I remember correctly I hammer-formed the horizontal return flange on the bottom side of this part (the flange that the bumper to body closeout bolts to) along the middle portion that had a slight curve but welded the flange on the tightly curved area to make the fab a bit easier.
1949 Chevy Panel Truck A Project Journal I'm old but I make up for it by being immature.
