This page describes how I am making new patch panels for my DIVCO. These patch panels are for replacing the panels in front of the side doors. Also, I am making new Inner Fenders Wells.
This panel is basically flat except where it bends into the door frame and then where it meets the fender it has a 3/4" raised and rounded bead. My first task is to create a form to press this bead.
Creating the basic under frame of the press using 4X4 angle iron.
Adding a solid core plywood base that is cut to the curviture of the fender.
To create the form for the bead I cut a 1" oak dowel lengthwise to create a 1/4" tall X 3/4" wide bead. Then steamed it (above) to make it flexible enough to form the curve.
This is a 2" copper tube that I am boiling water in while having the oak inside.
Pressing the oak strip into the form to create the curved bead while it is still hot.
The completed press. Overhead is two 4" angle irons welded into a box.
Pressing the bead.
Oak strip in place.
I used a 2X10 over the aluminum plate.
I added two 4X6 I-beams under the press plate for more strength. These two pictures are of the completed bead on a passenger side patch panel for a Model 13 using 20ga. steel which is the correct thickness.
Finished patch panel. The panel on the right is one I purchased last month. I was fortunate to have one to take measurements from. The panels above will fit the 11 and 13. I am not sure if they are the same size as the 12 or 15 series, but most likely they are the same. These panels measure 14" across the bottom and 38" across the widest section from the door edge to where the hood meets the fender.
The corners take the most pressure from the press so I made those forms using aluminum. This will provide a crisp & clean looking end to the bead.
20 ga. Patch panel on the form with the 1/4" aluminum pressing plate on top.
This is the completed bead for the driver side panel.
Still in the press.
Finished Patch Panels
I also made forms to make patch panels for the 100-300 series DIVCO. Wouldn't you know that two years ago I replaced the panels on my truck with flat panels. I suppose now I've got to tear them off & put on these new ones. They'll look great.
300-DIVCO Panel
300-DIVCO Panel
Making Patch Panels
Making Inner Fender Wells
Here is a driver side inner fender well. Last year I removed the rust & made patches for the missing steel. It didn't turn out quite right so I've decided to make new ones.
Rusted Inner Fender
Hammer Form or Buck
Please check back as I will complete this article soon.
This fender is made up of three pieces, the inner piece and the front and back piece. First I used paper to make a pattern of each piece. Then traced that onto 3/4" plywood to make a permanent pattern to cut the steel from.
