When performing bodywork on an older 4x4 you’ll occasionally find that the path of least resistance to the repair is to remove and replace a body panel. This could be due to rust or severe damage that you can’t pound back into its original shape. Sometimes a replacement panel is available from the aftermarket and other times you have to custom-make your panel out of flat sheet steel. This is something we’ve ended up doing several times, and we can give you some tips and tricks to make the job easier.
• The Thickness of the Metal Matters
One of the most important pieces of information you’ll need to know is the thickness of the sheet metal. Generally, thicker sheet metal is easier to weld to, and older 4x4s use thick sheet metal. Knowing the thickness will also help you set up your MIG welder so you won’t blow through the material.
• Spot Welds
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