Tolex for 1/2" Tick Back Panel

[roboDNA]

Hello,

I'm looking for advice on the best way to tolex this back panel around the vents.  I tried applying the tolex on the side which has the 45degree chamfer, and now trying the opposite side since I think I can hide the gaps better.    In one picture I'm showing how I used purple paint to hide the gap, with the chamfer facing inside the cab instead of outwards.

[acheld]

Well, there's no getting around gaps when you have an inside corner.  It's just a fact of geometry, and it's not easy.

If you use the side of the panel with the 45deg facing out as the Tolex side, your gaps will be smaller.  You just might be able to stretch your Tolex so there is no gap, but I think that's unlikely. 

On the other hand, if you have the 45 deg angle on the inside, the gaps will be larger, but you won't see them as much.  And may be easier to repair said gaps which will be inside of the main panel. 

Best way to do this is to fit the main part of the Tolex, with gaps, and let it dry.  Sometimes the glue will allow some stretching, but I find the Tolex will shrink when it dries.   When it is good and ready, maybe a few days, then come back and carefully cut patches to fit your gaps.  This will look better than your paint, though paint can be a good filler for small sliver type of gaps.

Real important to use a fresh razor blades.  I make no more than a few cuts with each end of the blade.   

Fender does it this way, though I think they do it all at once.   And the folks doing the work are so skilled they can make it look fantastic and do it in a heartbeat.