New Kick Panel for 1st Gens

VANagain wrote:I finally got the latest panel from my laser guy! This is the one with jute spray-mounted to the back of the black chipboard. (It is blacker than it appears in these photos.) The laser cut through the board just fine but it didn't get through all of the jute. Next time we'll try a higher setting on the laser but he didn't want to go too high because the laser can leave a burn mark on the surface. You can see some of that on the close-up below.

So now I need to use a sharp blade to cut the remaining strands of jute to remove the cutouts. More photos soon!

That's sweet! I had to comment to follow this thread. We're all interested to see the final result secured in place! I didn't want to be like No1Rascal "Any updates? Any updates?..."

Just trying to keep the thread alive, very interested in this.
Sorry if some people consider it offensive.

Offensive is such a strong word. Just ribbing you buddy. All in good clean fun.

,,,,,,Ok guys,,,,,let me go drop VanAgain a hint to update us on what,,,,,,if anything, is happening with his panel,,,,,,,,,,,,

Okay, Don did prompt me, but I had a lot going on, and I'm easily distracted.  

I took a sharp knife and ran it through the laser cuts to slice through the jute where it wasn't quite cut all the way. It came out real nice:



This photo shows the plan for attaching the two halves. As you can see, where the two panels meet, I left two bare areas (no jute). The idea is to spray (or brush on) contact cement onto these bare areas, and onto a 4" strip of jute. While the contact cement is getting tacky (10 or 15 minutes), put the two panels in place in the van, then stick this jute strip in place. It should act like a big piece of duct tape to hold them together and flush with each other.

Right-click and save this photo to see it larger. If you just click on it, ServImg will show it a little larger but it won't show it fullsize:



Actually, it would be easier if we apply the strip to one panel before putting it in the van, probably the driver's side. Then there would be no time limit on fitting this one in place, which is the trickiest. Then apply contact cement onto the passenger panel and the overhanging portion of the jute strip, let it get tacky, and pop that panel in.

I put the seam between the panels here for a couple reasons. Other locations would have weakened key openings (like where the wire loom comes through). And it will be somewhat hidden by the heater box.

And see that little hole right along the seam? The panels have a cut in them from that hole up to the top edge. And this hole is where the panels have horizontal scored lines so the panels can bend (fold) where the metal bends.

That's my next step, to determine the best way to score these. It was easy to fold the corrugated plastic panels, since their "corrugation" runs that way. On the stock panels, they must have used a press to stamp in an 1/8" wide groove where they wanted them to fold. I'd like to try something like that but not sure how (a hammer and a piece of 1/8" thick steel?). On a text scrap, I tried lightly running a blade along the back side, through the jute and just barely into the chipboard. This did the trick but I'd rather not weaken the panels. It would probably be fine though.

What do you think?

What about some kind of bead roller? Or maybe clamp it in a sheet metal brake and give it a fold where you need. Might have a hard time folding that material without breaking or cracking at the surface. Not sure what it is, kind of looks like hardboard or masonite?

Fabulous! I would buy one, and I don't even own a van...

I found the perfect tool to put the creases in the kick panels. Seth, you had the right idea. It's a tool used when replacing the screen in window screens, to press the beading into the frame. This first photo shows three methods I tried on a leftover scrap. The crease on the right turned out best, rolling each end of the tool along a straight edge, pressing real hard. Then, with the straight edge still clamped on the board, I lifted up the board, kind of like a sheet metal brake, to fold it along the crease.



Here's a close up of one of the panels. Turned out great, just like the original!!



This is the drivers side half. The other side is going to be trickier to bend because the crease is straight most of the way but then goes diagonally. Once that's done I can finally put them in my van for the final test fit!

Looking good Vanagain!!!!!!!!!

Nice Work Rich!!! I'm sure that all the Chevy guys appreciate all the hard work you've put into these panels. I don't think you'll have any trouble selling a bunch pretty quickly once they are completed...

Great work, and thanks for the update!

Here are the creases in the kick panels. I clamped a straight edge in place, ran that window screen tool along it, and then, with the straight edge still clamped, lifted up the panel to get it to fold along that line. This chip board is pretty tough. Took quite a bit of force to get it to bend to the slight angle we want:



Folding the half with the angled crease was tricky but I got it by clamping a second short straight edge along the angled part:

I added those creases a couple weeks ago. Today I got the left half installed in my van!!

I started with the left because it is tricky to fit in around the steering column. The corrugated plastic version folded here and there while installing, and the resulting additional creases didn't look too bad alongside the more subtle corrugation lines. But I didn't want any additional folds or creases in this one. This chip board is very firm, though, and resisted creasing as I bent it to get it past all of the metal parts of the dash. I had remove the left headlight "can" and get the fuse box and all of the wires tucked up into the dash area to get more clearance. I took some photos showing the steps that I will post soon.

For now, here's a shot of it in place!! (This shows the fuse box and wires dropped back down now that the panel is up against the "firewall.")



Looks like a good fit! I'll get the right side in and give it all a good once-over and report back.

Bravo! You are doing some great work on these

Rich, your doing all the Chevy guys a major solid with this project. Thanks for going the extra mile!!!

Looks great! excellent work, thanks for keeping us updated.

I am ready to buy one - what a great job.

Here is the right half of the final kick panels. This half is real easy to put in place.



This shows the seam where the two pieces meet. Good snug fit. I have not glued the two halves together yet. That's why you see some jute showing through that upper opening. And the seam will only be glued up to the fold. From there up, the two halves will not be attached to each other.


I am satisfied with all of my dimensions, so I'm ready to get a bunch of these cut. (I'll be leaving this one in my van, so I can finally put the all the stuff back in the dash!) To determine pricing, first I have to nail down what my laser guy will charge. Then I'll add up the cost of materials.

Those of you who are interested will have to decide between this chip board or the corrugated plastic. And I can offer them without the jute on the back, at a lower price, if you already have some insulation of your own, or just want to skip it.

We're getting close!!

Wow that looks great, excellent fit.
Looking forward to ordering one.

Thanks for all ur work on this.

Scott

Any idea on pricing

My laser guy said the layout of the panels on the board was actually too big for his laser bed. He had to cut on half, then reposition it to cut the other half. I need to come up with a layout that can be cut all at once, to keep the cost down. And/or find chipboard sheets that come in a different height/width. Stay tuned...

Please ad me to the list. Killer work!

Very nice

Add me to that list as well please. Thanks!

Any updates on this?