240D quarter panel rust repair
 

I've started tackling my rusty quarter panels. This is what I've done so far. More pics will come as the repair progresses.

Here are some pics of the fabricated patch.

Nice work that's a tricky bit of the car just there. It gets all of the muck and gunk from the rear wheels and takes a hammering from the inside too if your rear window (on a sedan) leaks...

How are you forming your repair patch? Are you lucky enough to have stretching and shrinking jaws?

Thanks. Yes, I have a shrinker/stretcher which has proven to be very helpful. I'm now working on a patch for the rusted wheel arch area. Even though this area is not really visible, I'm trying to reproduce it as faithfully as possible. I should get more pics up within the next week or two.

Oh no not the bit above - that looks like a tricky double walled bit. They do see repair panels for those bits over here - but if making it is the fun then I for one would love to see how you get on.

Not that much fun! I will buy a repair panel for the other side. From now on I'll devote the fabricating bit to panels that I cannot purchase.

I'll keep following this thread as this is a repair I'm going to have to do pretty soon!

Is your wagon china blue? I'll be posting more pics in the next few days as my repair proceeds.

Yep, sure is. I attempted to repair it but the rust just came back =[ Basically I need to do what you're doing and cut and replace metal in order for it to work.

Here are some more photos. I've fabricated a piece of the wheel well/arch.

Here is the piece tack welded in place.

Wow that must have been tricky tack welding from inside the trunk => 3rd picture posted above

It is looking good though - are you planning to grind and smooth it all out?

Some of the welding that appears to have been done from inside the trunk was actually done from inside the wheel well. I've actually now finished it with a continuous bead and started grinding it flush. Progress is slow as my time is limited. I'll continue to post pictures as this progresses.

Nice Work!
 

I envy your patience and skill when it comes to fabricating those pieces. I would have cut them out of a PNP car but there's no real fun in that; other than sparks!

Anyway, keep up the good work; your car will thank you.

Here's a link to my rust project http://www.peachparts.com/shopforum/bodywork-repair-paint-tools-tips-tricks/286242-staggerlees-rust-repair-thread-1980-300td.html

Staggerlee, I saw your work. It is very extensive and impressive. I've decided to no longer fabricate stuff that is available for purchase. It is just too time consuming! From now on I will only make pieces that can't be easily procured.