Install Steel Roll Pan: A Step-By-Step Guide

Installing a roll pan is a great way to customise the look of your truck, especially if you're not running a rear bumper. A roll pan is a fascia panel that fits against your truck, providing a smooth, flat appearance instead of a protruding bumper. It's a simple process that can be done in less than a day, but it's important to take your time to ensure a perfect fit. You'll need to remove your truck's bumper and taillight wiring, and you may need to fabricate a new panel if you're after a specific curve. You can then fit the roll pan, test it, and paint it to your desired colour.

Removing the tailgate and bumper

First, open the tailgate and release the straps that hold it up. You will then need to remove the pins on the hinge of the tailgate, which have a flat side that lines up with the flat side of the socket they are in. Lift the tailgate up and off the truck. Next, remove the license plate with a screwdriver and release the bolts in the well of the license plate. These bolts are attached to the bumper.

Now, move to the underside of the truck and disconnect the taillight wiring. Be sure to shine a flashlight under the truck for better visibility. Finally, remove the nuts holding the rear bumper brackets in place with a wrench, and pull off the rear bumper. With the tailgate and bumper removed, you can now prepare to install the steel roll pan.

It is important to note that some trucks, such as the 1956 Ford F-100, may require additional steps such as removing the lower side panels from the bedsides before installing the roll pan. It is always recommended to refer to your specific truck's manual or seek professional assistance if you are unsure about any part of the process.

Once the tailgate and bumper are removed, you can proceed to the next steps of the installation process, which may include test-fitting the roll pan, painting it, and securing it in place.

Preparing the roll pan

Firstly, open the tailgate and release the straps that hold it in place. You will need to carefully lift and remove the tailgate from the truck. The hinge of the tailgate has pins with a flat side, so make sure to align the flat side with the socket it sits in. This will ensure a proper fit during the installation process.

Next, remove the license plate using a screwdriver. You will also need to release the bolts in the well of the license plate, as they are connected to the bumper. It is important to keep track of the bolts and screws removed during this process, as they may be needed later.

Then, go underneath the truck and disconnect the taillight wiring. Be sure to have a flashlight with you to illuminate the dark areas. This step is crucial for ensuring a clean and safe removal of the rear bumper. Once the wiring is disconnected, remove the nuts holding the rear bumper brackets in place using a wrench. With the nuts removed, you can carefully pull off the rear bumper.

Now, you will need to prepare the truck bed for the roll pan. Fit the lower edge clips of the roll pan over the end panel of the truck bed. Gently push the roll pan until it is aligned with the top edge of the truck bed. This step ensures that the roll pan is properly positioned and secured before final installation.

At this point, you can use a piece of masking tape to hold the roll pan in place temporarily. Reattach the tailgate to the truck and check the positioning of the roll pan. Make any necessary adjustments to ensure it is exactly where you want it. Once you are satisfied with the positioning, remove the tailgate again.

Finally, you can test-fit the roll pan. Drill screws through the drilled holes along the top edge and drive additional screws into the lower corners of the pan. This will help you ensure a proper fit before proceeding with painting and final installation. After testing, remove the screws and the roll pan.

By following these steps, you will have successfully prepared the steel roll pan for your truck. Now, you can proceed with painting the roll pan to match your desired colour and style. Remember to let the paint dry completely before reinstalling the roll pan and completing the installation process.

Test-fitting the pan

Start by fitting the lower edge clips of the roll pan over the end panel of your truck. Slowly push the pan until it is lined up along the top edge with the bed of the truck. You may need an extra pair of hands for this step to ensure the pan is held securely and accurately.

Once the roll pan is in position, use a piece of masking tape to temporarily hold it in place. Reattach the tailgate to the truck. Check if the roll pan is aligned correctly by observing its position from different angles. Make any necessary adjustments by moving the pan until you are satisfied with its placement.

Remove the tailgate again and proceed with the test-fitting. Insert screws through the drilled holes along the top edge of the roll pan using a power drill. Drive additional screws into the lower corners of the pan for added security. This step will help you verify the fit of the pan before moving on to the next steps of painting and permanently installing the roll pan.

After you are happy with the test-fit, remove the screws and the roll pan. Now you can paint the roll pan as per your preference. Allow sufficient time for the paint to dry completely before reinstalling the pan.

Finally, replace the roll pan on the end of the truck and secure it with the screws. Reattach the license plate light and put the tailgate back on. Reconnect the wiring underneath the truck, and your new steel roll pan is now installed!

Painting the roll pan

Before painting the roll pan, ensure that you have test-fitted it to your truck. You can do this by inserting screws through the drilled holes along the top edge with a power drill, and driving an additional screw into the lower corners of the pan. Once you are happy with the fit, remove the roll pan and prepare it for painting.

Clean the roll pan to ensure that the paint will adhere properly. Use a mild soap or a degreaser to remove any dirt, grease, or oil. Rinse the pan with clean water and allow it to dry completely.

If necessary, use a primer to prepare the surface of the roll pan for painting. This will help the paint adhere better and provide a more durable finish. Follow the instructions on your chosen primer for the best results.

Choose a paint that is suitable for metal surfaces and follow the manufacturer's instructions for application. You may need to sand the roll pan between coats of paint to ensure a smooth finish. Allow the paint to dry completely before handling or installing the roll pan.

Once the paint is dry, you can reinstall the roll pan onto your truck. Follow the installation instructions provided with your roll pan, or refer to a professional if you are unsure.

Remember to take your time and work in a well-ventilated area when painting your roll pan. This will help ensure a high-quality finish that will last for years to come.

Final installation

Once you are happy with the fit and appearance of the roll pan, it is time to secure it in place. If you are welding the roll pan, you will need to clean and prep the weld surfaces, ensuring they are free of paint, dirt, and underseal. Use a stripper wheel to help clean off any residue.

If you are bolting the roll pan, you can use the original installation hardware or the hardware provided with the roll pan. Drill screws through the top edge of the roll pan and into the lower corners to secure it in place. You may also need to drill holes for the license plate light and fuel filler door if they are not already cut out.

After the roll pan is secured, you can reattach the license plate light and reattach the tailgate. Reconnect the wiring under the truck, including the taillight wiring.

With the roll pan installed, you can stand back and admire your work! You have now successfully installed a steel roll pan, giving your truck a smooth, flat, and customized look.

Frequently asked questions