Since I had cardboard that was falling apart, I used that as a template and adjusted it as needed since my truck isn’t square. Next, I used a drummel with cutting wheel to follow the line (very slow). Finally, held it close and heated the ends to mold it as needed. No painting!
Things I recommend. Make back panel longer due to cross member support. It slides in farther than I excepted. My cardboard must not have been slide in far enough.
If you get the 4x8 piece you can do both doors and roof panels.
I will post more once I do side panels. I am debating on doubling up Formica instead of aluminum.
I don't know Chris. I've owned a few of these trucks and none had kick panels of any sort. They were all just painted. I always paint the interiors in catalyzed enamel or catalyzed urethane help keep from scuffing as much. The first one I saw with kick panels may have been in the early 1960s. A friend bought a 1965 brand new and got the deluxe model...it had A/C and kick panels. One of the nicest pickups I've ever seen until he traded it in on a 1968. Gas mileage was comically bad but you could ride in the thing all day long and not be tired.
~ Jon 1952 1/2 ton with 1959 235 | T5 with 3.07 rear end
I ordered 2 pieces of 12" by 36" sheet aluminum that is .050 thick from McMaster Carr and a roll of maroon vinyl from Jim Carter. I then removed the old panel and traced it over the aluminum sheet with a sharpy. Cut out the aluminum with a nice new metal blade for thin metal with a jigsaw and then drilled the appropriate mounting holes on my drill press. Did a quick test fit.
Steve,
Nice work on those door panels. I'm basically in the same boat with my door panels. I've ordered the .050" aluminum and have the material to cover the panels. Here's a couple questions for you:
Did you cut the aluminum panel the same size as the cardboard? I was thinking about adding 1/16" all the way around to keep the panel in the frame.
Did you have to clamp the aluminum when you cut it with the jig saw? It seems like it could jump around a bit or wander.
No, the aluminum is cut the same size as the replacement cardboard door panels, I would be careful about cutting it oversize, worrying that the metal frame would not go around. I did clamp it along a piece of 3/4" plywood and used a fine tooth metal jig saw blade. Another thing I did that I forgot to mention was place 2ea 3/8"thick hard bumpers above each door handle mechanism to give it enough clearance between the sheet aluminum and handle mechanism,otherwise the door handle will not want to return on its own after opening the door. The other fellow above bent his sheet aluminum to fit over the door handle mechanism.
1953 Chevrolet 3100 261 cu inch, sm420, 3.55 rear, torque tube still,omaha orange, still 6 volt, RPO green glass, side carrier spare, all done In the DITY Gallery Video of the 261 running
1964 GMC 1000 305 Big Block V6, sm420, the next cab off restoration
Well done Andy, looks so much better than cardboard.
1953 Chevrolet 3100 261 cu inch, sm420, 3.55 rear, torque tube still,omaha orange, still 6 volt, RPO green glass, side carrier spare, all done In the DITY Gallery Video of the 261 running
1964 GMC 1000 305 Big Block V6, sm420, the next cab off restoration
