- Thread starter Paulie73
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Misterg
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What I'd do now is cut the flange off the van where the patch is going to be - just the flange and about 1mm into the arch. Trim the flange part of your patch to fit neatly in the gap. You should then be able to lay the patch on top of the rest of the old panel and clamp it in place over the arch with the new flange lined up and forming a smooth curve with the rest of the arch.
This will give you a good idea of how well it's fitting - you can tweak things to get it laying flat and lining up.
With the patch still clamped in place, I'd take the outer part (the one you're going to tack on) and bend it, twist it and cut it until it lays as neatly as possible on top of the old panel, and makes a neat joint with the first part. You can then tack them together on top of the existing panel. (This only works where the curve is shallow and you can ignore the offset due to metal thickness.)
Trim the combined patch panel down if you need to and clamp it back in place with the arch flange lined up. Scribe around it to get the line that you will use to cut out the rest of the old metal (assuming you want to butt weld it).
There's probably better / quicker ways, but that's how I'd do it.
Morris
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I work on the basis that anything can be useful for
Your scrap pile looks like it could potentially be a forum holiday destination.
