Yes flap disk will work if you can get it in there?
I prefer using Die grinders with 2 inch sanding disks.

https://www.harborfreight.com/air-angle ... 32046.html

https://www.amazon.com/Grinder-Suitable ... 69746&th=1

https://www.amazon.com/Tshya-Sanding-Al ... 841&sr=1-6

Doright wrote:Yes flap disk will work if you can get it in there?
I prefer using Die grinders with 2 inch sanding disks.

https://www.harborfreight.com/air-angle ... 32046.html

https://www.amazon.com/Grinder-Suitable ... 69746&th=1

https://www.amazon.com/Tshya-Sanding-Al ... 841&sr=1-6

Yes got an angle grinder,one problem.Years ago my 6hp 33g craftsman air compressor was taking up too much space.Open rafters in my garage so one day a friend and lifted it up there. I had insulation up against the roof and an old house furnace for heat.
Fast forward a decade and new unit heater and garage door go in.A few years after drywall on the ceiling.I made an access hatch beside the AC incase.So now I only have a 3 season air supply.
Plan was to frame around and insulation etc and allow heat in,just hasn't happened yet.Maybe now that I seem to have more interest in Auto Body I should do something about it.
Where Im at chinook winds often come and swing temps above freezing, but I get a lot of water in my air lines if it isn't warm enough.
Maybe just poly over the compressor and pipe in heat would work.Im not sure.

So on to stuff I need to do before glueing.
I need to replace this area. See pic. Basically two 45* bends. I have 18g metal for the patch. I assume I’ll need to do a relief cut on the back side of these bends since I don’t have a brake I think it’s called?

I traced the shape.

Also these fender support bolts. So **** long. I can loosen it but getting it to come out all the way it will just break. Assuming cutting what’s sticking out is the answer? Thanks.

Ok so fender bolts are out. A little wire wheel and some spray and out they came. Managed some time for a patch. See pic.

Question regarding welding on the truck with batteries still hooked up? Seams some say unhook others say as long as ground is close and good you’re ok? What say you?
Thanks.

It takes less than a Minuit, Disconnect both terminals. might be over kill BUT its just a buttery connection? so what is big deal? so you may have to reprogram your favorite radio stations....
BUT hey its your truck You wanna risk damaging your electrical/electronics to the tune of Hundreds of dollars Feel free to leave it alone. Me ? I know what I am doing.

Do a little more now less to do latter.
Spend a little more now save latter.
Do it right the first time Save big time! No need to redo and enjoy thy efforts longer.

Their is a right way and a wrong way for every repair or process Adhesives are no different when done correctly the repair will last a life time, Done incorrectly it may fail driving over a speed Bump!

My 93 F250 4x4 diesel came from the Rust belt and Has close to 400k on it now and I have NO intentions of parting with it any time soon.
When I do repairs I do it right and I don't cut corners

Yes of course I disconnected the batteries.
So I think I’m just going to weld in this panel. Today I found a self darkening helmet for a good price. About the same price as a tube of panel adhesive.
Tried it out, very cool. My welds have improved 10 fold. Maybe not pro standards.
These patches will be hidden by the fender flare so was good practice.
Friend lent me a hammer dolly kit so played with that a little.
Ordered plastic wheel wells so waiting for those to arrive before I weld in the big panel.

A pic. Still need a few more yet. Talking my time
I think this is what you call booger welding haha.

I also cut out most of the inner wheel tub so now I have access to the back sides.
So reading here 2k primer on the back side and a skim of fiberglass bondo?

Epoxy is preferred over bare metal.

When welding your patches should have little or no gap.
Skip around and yes grind it off but continue till No gaps, no Holes, you can use a Light from behind to find Voids in metal.
Yes after epoxy a skim of Fiberglass filler is acceptable.