Fender apron and core support replacement

I know some of you have done this and I’ve seen bits and pieces around but not a complete start to finish replacement.


I drilled the spot welds out that connect the apron to the cab and the core support.






I was hoping I could get someone’s opinion on the aftermarket aprons you can got online for like 300 bucks same with the core supports. I live near a few Toyota auto reyclers but the aftermarket parts are still usually cheaper.

 

I finished drilling out the welds on the core support and got that out of the way I just need to straighten out the mount for the support and then order the replacement support and apron, no suggestions?

 

Use sheet metal screws to fit all the panels then hang fenders and hood and check fitment. Usually a hit like that willknock it out of alignment and need to be put on the frame machine

 

@02dubcab

First off, I am strictly an amateur trying to save a truck that had already arrived at the salvage yard and would have become buzzard food. I am not making a show truck here, just going for a solid repair. I have a minor bendin the bumper mount portion of the frame (not repairing), but nothing affecting front suspension.

I am rehabing a 1995 with a very similar hit on the LH side. Since the truck is a 95, I am trying to control costs by heatin and beatin out the parts that are basically hidden from view. I am at about $800 in parts. My radiator was pushed back almost exactly like yours. I did not remove the apron as you have CORRECTLY done. I am just trying to go as cheap as possible.

I have however ordered and received the following

Amazon:

CarPartsDepot FRONT BUMPER VALANCE APRON DEFLECTOR AIR DAM 95-97 TOYOTA TACOMA 4WD V6 4X4 NEW
Sold by: Make Auto Parts Manufacturing
$37.61


Depo 312-1515L-AS2 Toyota Tacoma Driver Side Replacement Parking/Side Marker Lamp Assembly
Sold by: Amazon.com Services, Inc
Return eligible through Nov 11, 2018
$29.82


Depo 312-55027-301 Shroud
Sold by: Amazon.com Services, Inc
Return eligible through Nov 1, 2018
$48.95


Denso 221-3138 Radiator
Sold by: Amazon.com Services, Inc
Return eligible through Nov 4, 2018
$104.84


Chrome on this bumper was good quality (from Taiwan).

Evan-Fischer EVA17372010320 Bumper for Toyota Tacoma 95-97 Front Bumper Chrome 4WD
Sold by: AUTO PARTS VALLEY Product question? Ask Seller
$102.48


DAT 95-97 TOYOTA TACOMA 4WD BLACK FRONT UPPER BUMPER FILLER LEFT DRIVER SIDE TO1088106
Sold by: DAT AUTO PARTS
Return eligible through Oct 30, 2018
$11.07

Remaining parts from Rock Auto

Bought "Certified" fender. I was not impressed since the front wrap around below the side marker lamp does not appear to have correct curvature. It doesn't match the curve of the bumper.

Also bought my grille, AC condenser, marker lamp, and headlamp assy (with backing bracket) from RA. All good. Be aware the side marker lights do not have chrome around the border. It is a flat silver colored finish. Does not match my original.

I was able to straighten out the body mount bracket and weld it back in place. I relocated it slightly to account for the down bend in that area on the frame.

My relay box got crushed but I have repaired the wiring, just not the bottom half of the plastic box structure. I'll be fixing, not replacing since that would mean the entire engine room main harness. Too costly.



I use my tractor as an anchor, hook a chain with a ratchet boomer, and hook to the front of the smashed area. I welded on a chain hook on the top rail near the front end of the fender and pulled mainly there and in the headlight opening. Heat with torch and crank on the chain.



I still have a ways to to, but you can see I am making progress. Those parts will be coming back off but are getting real close on alignment. I have about 15hrs labor in this so far.

 

@Wsidr1 Thanks for the input, sounds like we are in the same boat. I am also nothing close to a professional and on a budget. I have done the same repair on a Land Cruiser and it wasn't that bad and the Tacoma seems pretty straight forward. I tried the "heat and beat" method and wasn't getting where I wanted so I decided to cut out the core support because they are like $40 online. How did you like the fitment of the aftermarket fender? I am debating on whether or not I want to go to the wrecking yard and try and get some OEM stuff or just order a bunch of aftermarket parts online.

 

The aftermarket fender was a disappointment. I paid extra on Rock Auto for the confirmed fit version, but the front portion is not aligning so well to the bumper. This problem is not a result of the crash damage. The dimensions of the part are just not exactly like OEM.

All my other parts are working well as delivered. Fender, usable, but not without effort.

 

I ended up deciding to get a core support and fender apron off a 2001 2wd single cab tacoma at pick and pull in ranch Cordova, ca for $82.95. Although I was drilling spot wends for an hour and a half it seems to fit pretty good and beats the $400 plus shipping I would have paid for factory and aftermarket parts. I was wondering if anyone had a recommendation on the grey body paint for the fender apron id like it to match the rest of the truck as much as possible.

 

So the 01 core support wasn’t the best idea, in reality the right part was an 02-04 core support. The 01 seems to work fine I just and to remove a few tabs and weld on a tab for a fender mount or either side. Other than that I found a replacement hood and fender on Craigslist and wrecking yards and got new repop headlight and corner markers. I just need a grill and bumper and body work is done and I will just need to install the radiator and ac condenser and then get an air box and wiper fluid reservoir.

 

AWSOME

 

Got the grill and the lights back on I’m just waiting on a bumper and it will be about done. I had to take the dash out to weld the apron to the cab which added a lot of work but other than that and getting the wrong core support the repair wasn’t too bad.

 

Been finished and put about 2,500 miles on it and it runs like before just a little less dash rattle now that I got to tighten all the bolts down after 250,000 miles. Only thing still missing is the fillers under the lights.

 

Looks great, well done
I'll be doing the same here soon

The core support should've been the same between 1998-2004 if I remember correctly.
Also what spot weld driller did you use? When I drilled out my bedsides for my prerunner it took FOREVVEERRR just seeing if yours might be any better.

 

This was a fun post to read, job well done

-Mike

 

The core support is pretty much the same, there are just a few tabs that are different because of the different headlights on the 02-04 if I remember correct. I ended up just cutting them off the old support because they were still in good shape and welding them on the new one and it worked perfect. I just bought 5-6 harbor freight spot weld drill bits and they did great, I would just recommend using a center punch before you start drilling so the bit doesn't walk around on you. Also I would recommend pulling the dash and heater box out when you weld the new clip on because I almost caught the truck... and my house on fire welding the new clip on.

 

Okay cool, same one I was using. And I might just bolt everything on. Might be useful later if I need to get to some hard to reach areas

 

Don’t skimp on the spot weld remover. I used this one and it came with four tips. I only went through two tips and I did and entire bed with probably 100+ spotwelds.

Blair 11096 Cutter Set

$55 Blair 11096 Cutter Set

https://www.amazon.com/dp/B002XML5HK/ref=cm_sw_r_cp_api_i_ozi5CbGPE5DYA

 

Yeah when I did my bed it was definitely struggling at the end. Should've just used another one but meh..
I'll probably get those ones then, anything to make it last longer and go faster, especially since in the scrapyard I'll have to use an electric drill.

 

Another issue I had was the bit not being quite big enough like there was still some metal keeping it from detaching, I probably just wasn't centered on the weld correctly

 

Has to be perfectly centered or you get that issue.

 

Thought so