Sheet Metal Fabrication techniques, questions and help. "Tricks of the Trade"

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Russ Hanscom
Posts: 1397
Joined: Wed Mar 15, 2006 11:10 pm
Location: Farmington, NM


Postby Russ Hanscom » Mon Dec 26, 2016 2:49 pm

Got an old Landcruiser FJ 40 that had holes rusted in the floor pan. First attempt was to order a set of replacement panels that came with really wimpy dimples, nothing like the originals, so...

The floor plan plate took four 1 1/2" x 8 1/2" by 3/16" deep dimples. The plate under the pedals took a 1/2" x 12" x 1/8" dimple. Here are the results at this stage - the dimples came out just right - nice and crisp. These were made with simple metal dies - two plates with the male form on one side and the female form on the other side with some alignment bars between the two then a quick trip to the press. The plate is .030" thick. One dimple at the time for the four dimple part.

I have also used hardwood forms and have one going for an odd shaped dimple to cover the clutch slave cylinder.


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Re: Dimples

Postby BadDog » Mon Dec 26, 2016 6:27 pm

Nice work.
Master Floor Sweeper

Russ Hanscom
Posts: 1397
Joined: Wed Mar 15, 2006 11:10 pm
Location: Farmington, NM

Re: Dimples

Postby Russ Hanscom » Sun Feb 05, 2017 6:01 pm

Not my favorite sport, but it needed to get done.

Dimples done, the panels got welded in; lots of plug welds to attach to stuff below.

Once the floor pan, the trans cover had a rotted edge that needed to be replaced. That is now ready for final grinding and a spot of primer. Since this is an offroad vehicle, a few muddy shoes will cover up any imperfections!

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