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12-09-2011, 02:44 PM | #1 |
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How To Fix Uneven Panel Gaps
Uneven panel gaps drive me crazy, so I found a way to fix them. You'll need 1/8" steel welding rods, welder's magnets, a grinder, a welder, and a DA sander. A long, flexible straight edge will be helpful also.
Once you have the door or panel adjusted so that the body lines are lined up and the panel is flush with the surrounding panels, take a look at the gaps and figure out how big of a gap you want between the panels. You can get carried away with this, make a feeler gauge to check and make every gap dead even, or you can just even out the worst areas. Here's what I'm starting with. On this truck, I'll just be straightening out the worst areas as the owner doesn't want a full on show truck. The gap under the body line is a good bit larger than it is around the rest of the door. To start, bend the 1/8" welding rod to the shape of the door/panel edge and use magnets to hold the rod flush with the edge of the panel. Tack weld around the magnets to hold the rod in place. You can fine tune the shape of the rod to the edge of the door before you fully weld the rod on. Once the rod is tacked in placs you can fully weld it on. I like to do one spot weld at a time, skipping around to limit heat build up until all of the gaps are filled in. After fully welding the seam, grind the welds down flush with the door skin. I like to use a 4.5" grinder to knock down the biggest part of the weld bead, then switch to a 2" air grinder to finish off the weld. There will be smaller uneven spots that won't need 1/8" rod. Just weld up the edge enough to close the gap. Some areas will have a gap that is too small. For this you can't just grind the edge down because the edge will split. Grind it, then you'll have to weld the edge after grinding it down, and then grind the welds down to even out the gap again. Once you have the gaps even, take your DA sander and round over the edges of the areas you reworked so the edge will be rounded and smooth. Try to match the radius of the original edges the best you can.
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12-09-2011, 03:58 PM | #2 |
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Re: How To Fix Uneven Panel Gaps
thats some nice work man. i just started doing this to my tailgate on my 86 cause it didnt fit for s***. good layed out guide for others to learn. thats the name of this game
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12-09-2011, 04:07 PM | #3 |
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Re: How To Fix Uneven Panel Gaps
Here's what one looks like when all the gaps match. I made a feeler gauge to check and adjust the gaps until they matched on every panel.
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Project Goldilocks '66 C10 Short Fleet BBW Build '65 C10 Highly Detailed Stock Restoration Thread '78 Camaro Targa Roof Build '55 International Metal/Body/Paint Work '66 F100 Full Rotisserie Restoration '40 Packard 120 Convertible Coupe Restoration How To Restore and Detail an Original Gauge Cluster How To Detail Sand Body Panels, Edges, Corners, Etc Last edited by theastronaut; 01-18-2013 at 05:33 PM. Reason: Fix dead pic links |
12-09-2011, 04:09 PM | #4 |
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Re: How To Fix Uneven Panel Gaps
Thanks man, thats what the forums are for.
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12-09-2011, 04:20 PM | #5 |
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Re: How To Fix Uneven Panel Gaps
That blue one looks sexy. That's one of my pet peeves spend all that time on paint and body but don't fix the gaps. Money down the drain
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12-09-2011, 09:16 PM | #6 |
low n' slo
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Re: How To Fix Uneven Panel Gaps
Nice work! Can you use that same technique on the body itself? I have an unusual twist on my driver door side...and I need to close the big gap it shows but I was thinking of welding rods on the body.
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12-09-2011, 10:37 PM | #7 | |
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Re: How To Fix Uneven Panel Gaps
Quote:
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12-10-2011, 01:43 AM | #8 |
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Re: How To Fix Uneven Panel Gaps
theastronaut, what color is that?
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12-10-2011, 08:50 AM | #9 |
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Re: How To Fix Uneven Panel Gaps
It was suppose to be the original 64-66 light blue but its a little darker. I think I've still got the paint code at the shop, I'll try to find it.
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12-10-2011, 09:11 AM | #10 |
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Re: How To Fix Uneven Panel Gaps
Thanks for posting these pictures and explaining how to do it! Stuff like this is what makes this site the BEST
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12-10-2011, 10:44 AM | #11 |
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Re: How To Fix Uneven Panel Gaps
Nice!
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12-10-2011, 11:10 AM | #12 |
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Re: How To Fix Uneven Panel Gaps
we have been doing that for 30 plus years. good post however for people that have never seen it. I don't like doing it. some guys slit the panel and shift it over. whatever works sometimes you have to make it work
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12-10-2011, 12:40 PM | #13 | |
low n' slo
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Re: How To Fix Uneven Panel Gaps
Quote:
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12-10-2011, 03:51 PM | #14 |
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Re: How To Fix Uneven Panel Gaps
You make a slice with a cutoff disc on the jamb side, then pry it over where you want it with a screwdriver and then weld up the slice you just made.
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12-10-2011, 04:55 PM | #15 |
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Re: How To Fix Uneven Panel Gaps
Thanks for taking the time to teach us how to do it right! I am just about to start working on my doors and this is going to help me big time.
Thanks Ray ps the blue truck is perfect! |
12-10-2011, 05:35 PM | #16 |
low n' slo
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Re: How To Fix Uneven Panel Gaps
i see...
not trying to jack the thread but i figure i would post in here since its related... the jamb on my driver side looks twisted...it was hit on that side before i bought the truck. i replaced it with new metal but the jamb was still twisted at the top and bottom. could i weld rods to the actual jamb, or should it be split open and pushed over? I know its a little hard to see in the pics....i dont have a digital camera TOP BOTTOM
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12-10-2011, 08:48 PM | #17 | ||||||
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Re: How To Fix Uneven Panel Gaps
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Project Goldilocks '66 C10 Short Fleet BBW Build '65 C10 Highly Detailed Stock Restoration Thread '78 Camaro Targa Roof Build '55 International Metal/Body/Paint Work '66 F100 Full Rotisserie Restoration '40 Packard 120 Convertible Coupe Restoration How To Restore and Detail an Original Gauge Cluster How To Detail Sand Body Panels, Edges, Corners, Etc |
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12-11-2011, 02:12 AM | #18 |
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Re: How To Fix Uneven Panel Gaps
astronaut - what great work ! gaps are so very even - i am sure that took alot of time
great lookin truck also - kudos man ! |
12-11-2011, 02:46 AM | #19 |
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Re: How To Fix Uneven Panel Gaps
Once again,,,,very nice work,,,,thanks for the thread.
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12-11-2011, 06:04 PM | #20 |
low n' slo
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Re: How To Fix Uneven Panel Gaps
Will do...thanks for the nice write up!
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12-18-2011, 08:05 AM | #21 |
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Re: How To Fix Uneven Panel Gaps
Very good work and great idea.
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01-17-2012, 12:19 AM | #22 |
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Re: How To Fix Uneven Panel Gaps
I Just finished replacing LH cab corner, RH cab corner, rocker, outer floor patch, A and B pillar patches. When I started all this my passenger side door gap didn't look that bad. But once all the work was done it looked off. The gap between the B pillar and the door is wider than anywhere else on the truck. I never heard of the split and pry method until tonight. My problem is the guy at the paint store told me a little -evercoat rage gold- in the door jamb is fine as long as its not thicker than 1/4". So I went for it. I built it up 1/8 to 3/16. Now its in primer. What are the odds the paint will crack there? Should i go back and do it over?
P.S. the rod welded to the door method won't work for me. The door looks perfectly straight. The gap between the bottom of the drip rail and the bottom of the door is whats off. From the bottom of the rail up is good. below tapers out towards the bottom.
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01-17-2012, 01:00 AM | #23 | |
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Re: How To Fix Uneven Panel Gaps
Quote:
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01-17-2012, 01:28 PM | #24 |
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Re: How To Fix Uneven Panel Gaps
If only I had read that 4 weeks ago...
I'll sleep better knowing that this was an "approved" fix method! An aluminum (or non-ferrous metal) backer plate under the edge weld helps to keep it from blowing or falling off when welding. |
01-17-2012, 07:03 PM | #25 |
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Re: How To Fix Uneven Panel Gaps
These are the only 2 pictures I took that really show where the bondo went. I sanded 90% of the stuff off then primed. The thickest spot is around the bottom rear corner of the door jamb. about 1/4" across once sanded. from there to the start of the drip rail it feathers down to zero filler.
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