Quote:
Originally Posted by 1955cj5
So my other idea was, to make a backing plate larger than the hole, install it on the fuel tank side using panel adhesive to attach it, then cutting and fitting a patch for the hole so the repair is flush with the firewall, and then the bracket goes on....
Ideas?
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You pretty much have it figured out already. Just skip the panel adhesive and weld it. This is what i'd do:
#1- Remove the tank.
#2- Cut a tight fitting patch panel same thickness as the firewall and make it fit flush with the surrounding metal. No over lap. (If you're using a mig welder, you can leave a slight gap between the perimeter of the patch and surrounding metal. If using a tig welder, make the patch fit tight.)
#3- Cut a reinforcement piece for the tank side of the firewall. There should have been one there already. Just match its size.
#3- Drill (4) 3/16" holes through the firewall in the area where the corners of the reinforcement plate will be. DO not drill the reinforcement plate. Just the firewall. Use these holes to plug weld the reinforcing plate to the firewall.
#4- Fit your patch panel into the opening and carefully weld around the perimeter, but not all at once. Skip around so it doesn't get too hot and warp.
#5- Grind welds flush, and reinstall the bracket.
You should end up with an undetectable repair on the outside.