Building floor patch panels is almost never fun, and usually involves either replacement panels from the aftermarket that you cut and massage into place, or a series of small pieces put together to create one replacement floor area. Unfortunately, scenario number two becomes more likely when you aren’t working on something super popular to restore like a Camaro or Mustang that has every single replacement part available. Such is the case with this 1958 Chevrolet station wagon. It has some rust underneath the back seat, in a spot that holds water if the windows leak and that isn’t readily available in the aftermarket.
What’s cool about this video is the fact that the panels are not made from a bunch of tiny pieces, but rather from a single piece that has been hammer formed into the stock floor shape. Yep, and with simple tools to boot. The only trick tools used here aren’t necessary to make these panels, and include the English Wheel and Planishing Hammer, but you could live without them for sure. The English wheel is actually being used like a tipping tool, or tipping dies in a bead roller. The planishing hammer is being used to smooth out some hammer marks but you could do this with a hammer and dolly and then some sanding for cleanup.
At any rate, you are going to want to watch this one and use some of the techniques on your next project.