Thread: Chevy Task Force Truck windshield panel fabrication

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I also did an end piece using hand tools only, to show it could be made either way. (Someone shouldn't be intimidated for lack of fancy tools).

Layout of the end only "patch panel"







To form the upper flange, a shorter piece had been cut out and clamped to the back side, and a slightly dulled chisel used to form the offset.









The pattern was clamped back onto our work piece to mark the bottom bends/lower edge for cutting.








Next, as we will be hammering, I chose to use the tipping wheel on all the bend lines simply to make a better mark and keep the marks more visible.








"Custom anvil"





Used a body hammer on the flatter areas, and a dead blow in the radius to minimize any stretching....








First bend at a full 90, seems to pull the panel to fit the radius pretty well.








Continuing to the other bends, still using the round stock anvil, I did get to where I had to go back to incremental bends again when I got deeper into the radius...








After a bit of Lancaster shrinking along the edges, it was fitting pretty good..








The hammered version would need a bit more cleanup work, but a comparison between the two shows it definitely would be a viable option for someone without the bead roller.

To finish off this thread, here are some installation details by the owner:

Originally Posted by olddaze

I got the panel from MPandC and I can tell you guys, It's quite a piece of work. Thought I'd snap some pics and include you on the install.
Here is what I started with.





And I cut away a rotten area inside the cab. I was alittle worried that this might cause the piece down close to the windshield would get really wiggley while I was working. Access to the inside was nice though





First off I dusted alittle paint over the spot welds and when dry, I scuffed it off with some 80 grit. Makes the spot welds show up better. Hit then all with an 1/8 bit and then followed up alittle bigger.





I thought the welds along the windshield edge would be the tough ones. I was wrong, broke most of them loose with a putty knife.








Comparing new to old:





First hurdle I ran into was just getting the panel in there. I had to open up the roof edge on the corners so I could roll the new panel in.





I also cut the panel in half to ease the work load and take the worry away of both corner being where they needed to be.








Worked out GREAT! About two days of fitting and 15 minutes of welding. Outer panel is all installed and I couldn't be happier with it. Huge thanks to MP&C

Looks like it worked well for him, another Stovebolt on it's way back....