Front sheet metal

[CHKNFKR]

Anyone have a breakdown of the inner fender for a gen 3? Getting ready to wear out a drill bit but i've noticed this panel is actually several overlapping pieces spot welded together. I'd like to remove the inner fender panels from the cab without puting any un necessary holes in the cab or cowl.

 

[alwaysFlOoReD]

You can buy a specialized bit for drilling spot welds, so you won't drill through both, just the outer one.
Post # 102;
http://www.therangerstation.com/forums/showthread.php?t=79003&page=7

Richard

 

[CHKNFKR]

I'm just going to drill through both and bolt the new sheet metal on, that way it's easily removable later on.

The gen 3 is a little different, particularly on the driver side, mine appears to be composed of three separate panels that overlap. Looks like theres the main panel, a stiffener panel on the outside that goes all the way back between the door hinges, and another stiffener on the inside just below the cowl. I think the driver side is beefed up to better support the battery, fuze box, etc... The passenger is just one panel.

I'll finger it out i suppose.

 

[alwaysFlOoReD]

I thought of bolting mine too but decided lots of little self tappers would be just as strong and less labor. From the three front clips [gen 1 and 2] I've looked at there is no exact pattern of weld spots so holes wouldn't line up anyway. But maybe my self tappers will rust out quicker, I don't know, just guessing that they'll hold.
Good luck,

Richard

 

[CHKNFKR]

Thats the other thing, i may not even put the inner sheet metal and core suppirt back in at all. Might just build a small frame to bolt the outer panels and header panel to and call it a day, i'm gonna need all the real estate i can get under the hood. I need enough space for a big block and a third member the size of a big block.

 

[CHKNFKR]

Welp i ran out of sunlight before i got either side off. Every time i thought i had the last spot weld i found another.

 

[nitrofan1]

Will this help???

 

[CHKNFKR]

Will this help???

Not really, im down to drilling spot welds at this point. I just had a hard time seeing what layer was welded to what, pretty sure i've got all but a couple welds drilled out without accidentally puting extra holes in anything. *fingers crossed*

 

[alwaysFlOoReD]

On my gen one and two there are 27 spot welds per side [edit; to remove the front clip as a whole].

Richard

 

[CHKNFKR]

Ended up having to drill out 30 welds to remove the stiffener panel on the driver side, 11 of those welds also held the fender panel to the cab. The stiffener had to come off because it covered up 4 welds. Once it was off and the 4 hidden welds were drilled there were 15 more welds to go.

The passenger side was much easier, 34 welds total 3 of which also held on an extension panel on the very front of the cab.

Ended up drilling out the last 2 welds with a nut driver because my drill stopped working. The motor was turning, but the drill head was not. Not sure what thats all about.