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- Dec 18, 2003
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This will be a mini build thread for my interior quarter panels.
1. Cut the panels out of masonite.
2. cut speaker holes and access panels for later
3. fiberglass the panels
4. Carpet the panels
5. Install rivnuts to anchor the panels
6. Install the panels and speakers.
I already had the masonite, so it was an easy choice to use it. This material is hot pressed saw dust, there are no glues or binders. It is extremely flexible and easy to work with. I used a jig saw for all of my cuts, but a circular saw will work for straights just as well.
Step 1:
The template was supplied to me by NGABronco, THANKS! Having a template saved a load of time vs building one from cardboard.
First I had to measure the dimension I wanted the panel to be. The stock panel, going by the template, is ~55x18 inches. I wanted mine to come right to the top of the bed rail, and just shy of the rear of the bed, so I made mine 54.5x19.
Once I had the rough dimension, I layed the template over the panel and lined up the wheel well. The template had the door jam to wheel well right at 10", however, mine measured 9.5". In the rear, the template was switched on the measurement, 9.5" on the template, 10" on my bronco. So it was a simple matter to match up the wheel well on the template to the leading and trailing measurements I took from my bronco.
I then traced the wheel well on the template with a razor, cutting out the wheel well.
And then painted the panel using the template as a stencil.
Then it was simply cutting along the edge of the paint to remove the wheel well from the panel.
I used the first panel as a stencil for the second. I know that this can compound errors, but I'm not really concerned. I did use a straight edge to clean up the straights portions, but since I am going to glass and carpet over the masonite, most errors will be blended in. At the end of the night, I have two interior rear quarter panels.
Now, since I have a 77, the drivers side will need to be fitted. The rear fuel filler neck protrudes about 1/4" beyond the wheel well face. I am going to remove the rear seat and test fit it to see if I want to cut around it, or if allowing it to bend will be sufficient.
Here's a pic where I just placed the first panel on the driver's side to check rough measurements. So far, I'm pretty happy.
1. Cut the panels out of masonite.
2. cut speaker holes and access panels for later
3. fiberglass the panels
4. Carpet the panels
5. Install rivnuts to anchor the panels
6. Install the panels and speakers.
I already had the masonite, so it was an easy choice to use it. This material is hot pressed saw dust, there are no glues or binders. It is extremely flexible and easy to work with. I used a jig saw for all of my cuts, but a circular saw will work for straights just as well.
Step 1:
The template was supplied to me by NGABronco, THANKS! Having a template saved a load of time vs building one from cardboard.
First I had to measure the dimension I wanted the panel to be. The stock panel, going by the template, is ~55x18 inches. I wanted mine to come right to the top of the bed rail, and just shy of the rear of the bed, so I made mine 54.5x19.
Once I had the rough dimension, I layed the template over the panel and lined up the wheel well. The template had the door jam to wheel well right at 10", however, mine measured 9.5". In the rear, the template was switched on the measurement, 9.5" on the template, 10" on my bronco. So it was a simple matter to match up the wheel well on the template to the leading and trailing measurements I took from my bronco.
I then traced the wheel well on the template with a razor, cutting out the wheel well.
And then painted the panel using the template as a stencil.
Then it was simply cutting along the edge of the paint to remove the wheel well from the panel.
I used the first panel as a stencil for the second. I know that this can compound errors, but I'm not really concerned. I did use a straight edge to clean up the straights portions, but since I am going to glass and carpet over the masonite, most errors will be blended in. At the end of the night, I have two interior rear quarter panels.
Now, since I have a 77, the drivers side will need to be fitted. The rear fuel filler neck protrudes about 1/4" beyond the wheel well face. I am going to remove the rear seat and test fit it to see if I want to cut around it, or if allowing it to bend will be sufficient.
Here's a pic where I just placed the first panel on the driver's side to check rough measurements. So far, I'm pretty happy.
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