Custom fabricated cover / filler panel for left rear underbody opening

[Telemachus]

I have thought about finding a piece of plastic but the biggest problem I see is where there needs to be a bend for attachment. I don't think heat that far back would be much of an issue but no reason not to stick with Galvanized Sheet Metal. Galvanized metal many times has a 50-70 year non rust time, even if cheap metal it should last 20 or more. A little rust along the edge where cut if it occurs who cares?

Galvanized spray paint the edges

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[KathyG]

More measurements.

As I stated earlier the overall size is about 14"X16.5" needed to do as I have but without the leg.
-With leg it's about 21.5" long and the 16.5" wide.
-15.0" is the width of the shield from inside edge of frame to inner fender. (1.5" more needed for bend down to attach to bolt at inside fender where I temporally have the clip in the photo)
-14.0"(maybe 13.5') is distance from inside inner fender well toward the rear of vehicle.
-About 2.75" down you need to cut back (about an inch) toward the front and cut down to give more room from the wires where wiring is a problem at the back of the shield. (I guess you can just make it 13.0'' and not notch the shield but may have a problem then using 18mm bolt)
-note: the edge along the inner fender is not straight, I've angled it in 3/4 inch due to frame to inner fender gets less as you go back.
-Without the leg there is nothing to support the back of the shield if you just make a panel 14.0"X16.5".
-leg is about 8.0" longer than the 14.0" shield thus the total length of the shield is about 21.5" total.
-at the back of the leg there is a plastic body panel that when the part of the leg is bent it can be attached easily with a screw to the plastic body panel.
-for clearance reasons the leg has to be cut at an angle, at the rear about 1.5" up from bottom of shield (not including the bend up at inner fender well.)
-I went to inside edge of frame so I could use the large 18mm bolt to support the back inside edge of the shield and drilled 2 holes in shield and frame and added 2 screws. (see photo)

Sizes are approximate and the shield can be made a little larger/smaller in most areas.

**I highly recommend making a cardboard prototype first and see what works best for you. As you fit it in you will see why I have the cut outs at inner fender due to clips that stick through. The leg to the back is a bit of a hassle. You can trim the cardboard as needed until you get a good fit. You do need the 1.5" bend to attach to inner fender bolt.

***Most important, looking at the inside of the fender you will see the bolt that sticks through that I have the clip on. There is a 10mm nut that looks like it can be unthreaded, It can't! I even went so far as using a cut-off wheel to try to cut the nut off, it's part of the fender brace and the bolt apparently threads through from the outside. Looking at it will make sense. I used a clip temporally (will get a "push on nut") due to damaging the bolt threads, my suggestion would be to use a threaded nut if possible to secure the shield at the inner fender.

photos with measurements are not to scale but will give somewhat of an idea of what I did. Hope this helps. Looks like I can't spell bumper.

THANK YOU mcc63303!!

Really nice of you to post photos and measurements of template! Thank you so much!!!

Kathy G

 

[mcc63303]

Hi, hope it helps. Best advise I have is to make a cardboard template first. I actually used several pieces of cardboard taped together before using metal. It's been 18 months since I made it and it's doing just as I hoped. I have a 2024 ordered (actually 2023 rollover) that I hope to get when Ford decides to make more XL Hybrids. I'm getting 47+mpg and couldn't be happier with my 2022; after I added the power tail gate lock and changed steering wheel switches and programmed cruise control.

 

[Mikknj]

More measurements.

As I stated earlier the overall size is about 14"X16.5" needed to do as I have but without the leg.
-With leg it's about 21.5" long and the 16.5" wide.
-15.0" is the width of the shield from inside edge of frame to inner fender. (1.5" more needed for bend down to attach to bolt at inside fender where I temporally have the clip in the photo)
-14.0"(maybe 13.5') is distance from inside inner fender well toward the rear of vehicle.
-About 2.75" down you need to cut back (about an inch) toward the front and cut down to give more room from the wires where wiring is a problem at the back of the shield. (I guess you can just make it 13.0'' and not notch the shield but may have a problem then using 18mm bolt)
-note: the edge along the inner fender is not straight, I've angled it in 3/4 inch due to frame to inner fender gets less as you go back.
-Without the leg there is nothing to support the back of the shield if you just make a panel 14.0"X16.5".
-leg is about 8.0" longer than the 14.0" shield thus the total length of the shield is about 21.5" total.
-at the back of the leg there is a plastic body panel that when the part of the leg is bent it can be attached easily with a screw to the plastic body panel.
-for clearance reasons the leg has to be cut at an angle, at the rear about 1.5" up from bottom of shield (not including the bend up at inner fender well.)
-I went to inside edge of frame so I could use the large 18mm bolt to support the back inside edge of the shield and drilled 2 holes in shield and frame and added 2 screws. (see photo)

Sizes are approximate and the shield can be made a little larger/smaller in most areas.

**I highly recommend making a cardboard prototype first and see what works best for you. As you fit it in you will see why I have the cut outs at inner fender due to clips that stick through. The leg to the back is a bit of a hassle. You can trim the cardboard as needed until you get a good fit. You do need the 1.5" bend to attach to inner fender bolt.

***Most important, looking at the inside of the fender you will see the bolt that sticks through that I have the clip on. There is a 10mm nut that looks like it can be unthreaded, It can't! I even went so far as using a cut-off wheel to try to cut the nut off, it's part of the fender brace and the bolt apparently threads through from the outside. Looking at it will make sense. I used a clip temporally (will get a "push on nut") due to damaging the bolt threads, my suggestion would be to use a threaded nut if possible to secure the shield at the inner fender.

photos with measurements are not to scale but will give somewhat of an idea of what I did. Hope this helps. Looks like I can't spell bumper.

That's quite impressive. Thanks for sharing.

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