The Stovebolt Site Forums The Shop Area Paint and Body Shop More questions about 48 two ton rust repair

Hello, Sorry for the wordiness. I mentioned I would be asking a lot of questions since this is my first big bolt (48 two ton). I have some questions about patch panels. I have looked at LMC, Jim Carter, Classic Parts of America, The Filling Station, Chevs of the 40's, and Brothers for the parts I will need for the left side of my cab. I will need the inner and outer cowl, the inner to outer cowl panel, the little filler panel where the fenders and cowl meet. Fender welting and fender to body gaskets. Some places call that anti-squeak, or inner fender gaskets.
I will check out who has the best price and availability. I made a little spead sheet. Right now I would like to know about the outer cowl piece. It has the small vent that you can open and close for fresh air. Do you have to cut out the existing door and fit it to the patch panel? On the inside cowl patch, do you have to also save the handle flange and cover for lever that opens and closes the small vent door?
As far as the vent door goses, how do you remove that? Mine is binding and I want to take it off and clean up the hinges. I have taken 4 screws off that I can reach through the door, but it doesn't want to come off. I don't want to force it, but is it possible that the parts are rusted together that should be separate to allow for the door to come off?

Just a heads up.
The patch panels look good but they do not fit correctly. You will most likely have to cut and refit them for your truck. At least that what I ran into.

I only cut and repaired the very bottoms that were rusted thru. When I had the area open I treated the exposed surfaces with rust converter and painted over.

Here are a few pics of the new inner/outer patch panel.
...pic 1...
...pic 2...
As you can see its not even close to fitting correctly. I finally cut the patch panel in three pieces, and patched it to the original.
...pic 3...
It looks ugly, this was my first time weld repair.

The inner kick panel didnt fit either. Had to hammer out the very bottom to get it to fit the floor pan and rocker panel
...pic 4...
...pic 5...

the creases and ribs in the panel line with with the door. so you will have to make sure they are in the right location befor you final weld.
...pic 6 ...

The new outer panel didnt fit correctly either. I welded it in place as it is formed. But should of cut and fitted it also with the fender and door installed.
I ended up with a gap.
...pic 7...
...pic 8...

One other thing, the patch panels I purchaed are not the same thickness as the originals. There is NOTHING better than original metal. I tried to keep as much original metal on the truck. Being a California truck it was in good shape.


Bolter Brad Allen has good pics of the vent door that might help you.

Hopefully others can advise about fitting the vent door for you. I cut just under it.

Good Luck

Thanks for the pics. I might be able to do the same thing with my outer cowl. I may have good metal that high up. I'll be able to tell once I start sanding away the paint. The truck I have was suppose to be rust free. I bought it off of ebay. It is turning into an educational project for sure.

i dont have a big bolt but I have all the same issues in my 1/2 ton having to completely rebuild the front corners. I am trying not to sweat it and just work on one thing at a time but I see it as I have no forward floor as its all rusted though and I have to forward corners once I cut them all apart so when I go back together with the forward corners I have no floor to weld the new stuff to......one thing at a time, one thing at a time, one thing at a time. and I am keeping my fingers crossed it just works out.

Yep... one thing at a time, but I have to admit, I am having a good time doing it and have met a lot of people through my truck. I like to take this work in a relaxed manor so I don't have to learn too big a lesson. Funny how some of the small stuff is the most perplexing. I am still trying to get that side cowl vent door off. I think I have some parts that should be moving but are rusted together (the little pivot pins) I may not get it working until I cut the inner cowl (kick panel) off. I was looking tonight and I might be able to save my inner to outer piece. In my mind that would keep the shape close to original even if I have to re-shape the new cowl pieces.

I have put together a price comparison list if anyone is interested in seeing it. go to http://share.shutterfly.com/action/welcome?sid=8Ibs2LFo3bsz-

The filling station is the only supplier that had listed the filler plates specifically for two ton, so the other suppliers plates may be too small. Also, some of the web pages were hard to find parts, so if it isn't listed I couldn't find the part.

Not sure how the anti-squeak or inner to outer fender gaskets would fit either.