Next phase is front fender restoration. Not going to easy considering the condition of them.
I started restoration of the right front fender. The first thing I needed to do was make a new mounting flange for the fender.
It was too rusted away to hold the fenders shape and hold the fender on.
Here is the start of the new heavy gauge flange.
After making the whole flange, I tacked it to the fender and bolted it on the truck.
Then I worked out the big lumps and bumps, plugged the step pad screw holes,
and got it shaped the best I could with what I have to work with.
Here it is shaped and mounted.
Next, I marked out where I wanted to make new patch sections.
I decided to make two new pieces to repair the damaged area.
The metal was just too thin from previous repairs to save.
The first step is to make paper templates of the patch panels.
The first paper template. Just fold the paper over to get it to the shape of the panel.
Same thing with the lower patch panel.
Then transfer your paper templates to your metal. Here I am using cold rolled 19ga.
Then cut out your pieces leaving a little extra metal around the edges.
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