Relocating Gas Tank - Clean-Shaven

We grabbed the tin snips and began to cut out along the line we scribed out.

Next, we grabbed a hand file and began to file the rough edges off the filler piece, finessing it to shape.

With our trim piece done, we now test-fit it to make sure it is a good, tight fit with very little gap.

Here is our filler piece in place. Danny drew an orientation arrow and then placed two index marks on both the filler piece and the cab to maintain proper alignment.

Using 2-inch masking tape to hold the slug in place, Danny tack welds several spots using a TIG welder.

We continued tacking, going every ¾-inch and in a slow cross pattern, moving from left to right.

A little hammer and dolly work as we go ensures that the filler piece maintains the correct shape.

Here is a close-up of our filler piece all tacked up.

Next, we will connect our tacks by welding from one to the other until the entire area has been welded.

Here is a close-up of the filler piece all welded in.

A hand file was used to knock down the high spots.

We sprayed blue machinist dye over our weld, which will show us our remaining high and low spots, then they are massaged into perfection using a hammer and dolly.

At this point our weld area still has a few high and low spots left. We will continue to knock down the highs and bring up the lows by alternating the hammer and dolly and filing techniques.

Once the repaired section looks nice and level, Danny loads the DA sander with 80-grit sandpaper, which is used to take out the scratches and file marks on our filler piece.

This is the finished area with everything welded and grounded. You would never know that there was a hole here at one time.