Diver side kick panel vent removal

[MikeB]

OK, I've got all the screws removed and I can pull the panel out an inch or so, but then the vent door surround (for lack of a better term) gets hung up on the hole in the body panel. Looks like I may have to remove the parking brake bracket, but that's not what the panel is hanging up on yet. Any suggestions?

Truck is an 82 model, if that makes a difference.

 

[PrairieDrifter]

A/c truck?

 

[78C10BigTen]

OK, I've got all the screws removed and I can pull the panel out an inch or so, but then the vent door surround (for lack of a better term) gets hung up on the hole in the body panel. Looks like I may have to remove the parking brake bracket, but that's not what the panel is hanging up on yet. Any suggestions?

Truck is an 82 model, if that makes a difference.

Try asking @legopnuematic, iirc he just took his out to do patching. He may have an idea. Granted his is 79 but....

 

[MikeB]

A/c truck?

No.

 

[MikeB]

Finally got it out. Not a pretty sight behind it. Lots of rust and some rust-through on the lower side of the opening for the vent.

 

[legopnuematic]

Finally got it out. Not a pretty sight behind it. Lots of rust and some rust-through on the lower side of the opening for the vent.

I have taken that panel on mine on and off multiple times and everytime it decides to change its way it wants to come out.

The good news is that with some scrap MDF and some 18 gauge CRS you can make it good as new.

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[MikeB]

That's some very nice work and has given me some idea. I have a buddy who's really into making patch panels, and he owes me for doing all the electrical wiring on his hot rod!

Here's my mess, and I expect the pass side is just as bad or worse.

BTW, how did you use the MDF, and what is the yellow/black piece?

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[Jrgunn5150]

Ouch, that's not good.

 

[legopnuematic]

The MDF is used as a 'hammer form'. So basically it has the feature that I want to be formed. In that case it was the bottom of the opening with the lip. I then securely clamped the patch to the MDF and used various hammers and mallets to slowly work the desired feature into the patch. The stripe piece is the MDF, it was an old locker shelf shelf I had laying around so I used it to make the hammer form with.

 

[MikeB]

Thanks for the explanation.

A couple more questions since you dug into the cowl a lot deeper than I hope I have to:

Is it normal for water to run from the cowl down in the cavity behind the vent and then out the bottom of the fender? If so, how does the vent panel design keep water out of the interior? Looks to me like if the vent was opened water would get in.

 

[MikeB]

Here's the "after" picture. The panel vent housing will cover up the welds.

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