I picked up a great condition original valence. I want to fill the openings for the backup lights. Can someone provide some ideas on how to do this properly so it will hold up? Welding technique to use? Source of patch metal?

Decided I will likely put a fiberglass rear bumper on and recess some type of back light under it.

 

Take a piece of 16 gauge sheetmetal and trace the opening on it. Cut to fit inside the opening. Tack weld in several places. Connect welds with a small bead (1/2"). Metal finish. Apply thin film of filler if needed.

Body shops are a good source for small scraps. Most metal shops want to sell whole 4x8 sheets. I hung on to the leftovers from my patch panels to use in the future.

 

I'd cut square patches out of the scraps, then trace around the round backup light holes. That way it's easy to know where to cut the valance, and easy to align the patch panel. This is what I did when I shaved my antenna.

 

Cut the valance instead of trimming the patch to fit? :scratch: That'd work too. Probably easier that way, Blake.

 

How about flanging the patches and drilling holes in the flanges. Then spot welding the patch from behind to hold it, followed by a bead to fill from the front. Grind and then fill? I'm trying to remember if there's some tough contour to match to the panel or if it is indeed flat there...

We're getting there

 

If there is a contour, it shouldn't be so much that you couldn't bend the patch to fit it.

The flanging will work just as well and may actually be stronger. I just prefer butt-welding when possible.

 

Agreed on both points.