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Fwd Filler Panel Clips

I had a little bit of time today so I focused on making the clips to stabilize the forward unsupported edge of the front filler panel that I made a few days ago. I had some small sections of 1/8 x 1-1/4 hot rolled steel in my scrap bin so I took a quick measurement of what I needed to fit the filler panel and cut four of them 4-1/8 long to use to fab the clips/brackets.

Yesterday I had soaked 4 zinc plated 5/16-18 hex bolts in vinegar to remove the plating so I wouldn't have to contend with removing the zinc when welding them. I then cut the threads a little shorter (so they would not stick out too far) and cut the hex head off the bolts to create a short threaded stud. I will use these to weld to the bumper brackets to attach the clips.

I then drilled the steel strips.... a 3/8 hole in the top flange and a 3/8 wide slot on the lower flange (to allow up/down adjustment of the clip). I also took a cut-off wheel and scored the clip at the bend line to make sure the part bent where I wanted it to bend. Once it was bent, using a hammer with the piece in a vise, I welded up the scored edge to add back some strength.

With the clips finished I then crawled under the bumper and laid out where to place them on the bumper brackets. I temp clamped them in place and marked the hole and slot locations on the filler panel and the bumper bracket with a white paint marker. I then removed the bumper, bumper brackets and filler panel and drilled the bumper bracket 5/16 dia for the threaded studs and the filler panel 3/8 dia. Next I welded the threaded studs into the bumper brackets at the marked locations.

Lastly, I remounted everything back in place, using some stainless button head socket screws to attach the filler panel to the new clips for a clean look. I then took a few pics to show you how it all ended up.

Next up will be to blow it all back apart and remove the rust and mill scale from the parts and prime everything....then on to the long list of things left to do.