Corrugated to flat transition

[gashammer]

Hello Friends,

I'm doing a job on an older Toyota Truck. Unfortunately, the panels which were provided for the bed are generic stampings and do not include the transition from the corrugated segment to the flat flange which is welded to the frame work.

For example:


I'm looking for suggestions/ideas on how to make this transition to flat without a lot of cutting and welding. I have a relatively well equipped shop, but no heavy machines (Pullmax, etc...)

Thanks for your expertise!

[Marc Bourget]

Can you provide a photo of the "transition" you're trying to duplicate?

[steve.murphy]

I’m guessing you want to make the end edges flat.
Perhaps you could make a fixture of sorts that allows you to clamp a bar under the raised corrugated part. Attached to the bar would be a wedge shaped piece that fits the inner corrugation that can allow you to hammer and tuck shrink the excess material down to a flat surface. Doing one at a time.
I seem to recall that the experimental aviation association had an article years ago about doing this on thier ford trimotor aircraft restoration in their Sport Aviation magazine.

[gashammer]

Not the same truck, but a good representation of what I'm up against:


I've been thinking of different ways, it's a lot to shrink. I'll get some images of the panel along with some measurements. I'm trying to avoid a bunch of fiddly welding and grinding across this panel.

Is there any chance of a link to the article?

Thanks!

[Marc Bourget]

Check out the thread entitled "GrandWillysProject"


Marcus documents this point and much more.


It's worth reviewing the whole thread, but he does address bed issues

[steve.murphy]

Im hoping someone else has done this, I’m curious about the process too.
I’m no longer a EEA member but they had excellent archives available to members.