Crusty rear body pan? not sure what to do about the weird shaped holes for the bumper bar? Fear not! With these parts you can get a nice rolled edge for the opening just like factory, and replace the reinforcement flange in behind the body pan as well.
I worked with 20ga steel for this project.
Print the bumper opening form, use the bumper opening template to drill the holes and cut the middle opening out (make sure to cut on the inner line so you have material to hammer into the opening!), and bolt the form to the metal and get to work! I mounted this into my vice for easier working.
I do not have files drawn up for the body pan pieces, as I worked these up as I went along and they also consist of a flange that meets up with the tail lamp panel.
For the reinforcement flange, it does have a step in it that isn't marked in my drawings, I compared this to the body and the old part in order to get it right. This was made using 16ga steel to match the original part. The top short edge is also bent inward at a 90 degree angle and inserts to a gap above the frame rail, some adjustments to the part may be necessary here.
| bumper_opening_form.stl | 56.5KB | |
| bumper_reinforcement_flange.dxf | 105.1KB | |
| bumper_reinforcement_flange_w_bend.dxf | 101.1KB | |
| rear_pan_bumper_opening_template.dxf | 103.3KB |
