I finally got the script Chevrolet trimmed out of the sheet after a few rounds with the die grinder, angle grinder and hand files. Once I got it cut out I marked a horizontal line on the tailgate/rear doors so I could align the two script halves on the doors. I then figured out where I wanted to fasten the script to the doors to hold them in place while the panel glue dried. Next I drilled a small hole just a little larger than the sheet metal screw in the two scripts and match drilled a starter hole on the doors with the scripts held aligned to the horizontal line.
Then I temp fastened the two script cutouts to the door and marked where I needed to slightly contour/bend the parts to better conform to the door shape. I clamped a dolly in the bench vise and them massaged the areas that I marked. Once I got the script to fit properly I then stripped the primer from the doors local to the bonded area, sanded the door and backs of the script with 80 grit sandpaper and then cleaned the surfaces with some lacquer thinner.
With everything prepped and cleaned the next step was to take the panel adhesive and apply a thin layer on the backside of the script cutouts. I then took the cutouts and attached them to the door panels with the self-tapping screws making sure to get good squeeze-out all around. Then I wiped off the excess along the edges and any stray adhesive.
When it dries I will remove the screws and fill in the screw holes. I plan on putting a thin coat of filler along the edges and then sanding it to blend it to the door and the bonded sheets so it looks like the rear panel was embossed. I'll see how it all works out. Nothing ventured, nothing gained, knock on wood and whatnot....
1949 Chevy Panel Truck A Project Journal I'm old but I make up for it by being immature.
