In this week’s video, my dad and I took on fabricating our own toeboard for my 1965 Ford Falcon. Old water damage had led to a completely rusted out toeboard, and thanks to COVID, every online retailer was back-ordered. So, we picked up some sheet steel and got to work. Needless to say, it was difficult, but it felt SO GOOD to get it finished!!
AirCat Air Saw: https://aircat.com/low-vibration-saw
Eastwood Products Used:
Rust Encapsulator: https://www.eastwood.com/eastwood-rus…
Rubberized Undercoating: https://www.eastwood.com/eastwood-rub…
Ellie,
Great effort! The next one will be way easier.
A good source of sheet metal is a local body shop. I made many Falcon patch panels from newer vehicles crash damaged panels. I found pick-up bed sides provides large flat areas. I would bring my removed rusted panels and often times I could find a piece where I could use existing bends. The bonus is newer vehicle sheet metal is usually coated to prevent rust.
If you had found patch panels, they would have taken quite a lot of bending/cutting/fitting.
One other tip is to place panel in oversize, temporary fasten with sheet metal screws, weld in a few spots to anchor it and then cut the old and the new at the same time. Just do about 6″ cuts at a time, tack weld and then cut some more. You can also hammer as you go to improve the fit. The patch panel is easier to mold into place went it is firmly attached in a few places.