Task not as hard as I thought! - Pics

[pwogaman]

Aside from the rust I've already cut out in the rear of the quarter panel extensions as shown in another one of my treads, I had one little nagging sopt of rust I never really wanted to get to because it would have to cut into the paint - yikes! Well, while I was at it with the trunk rust I went ahead and bit the bullet.

The first (and only) picture is the rust as found - although I should have taken more.

The next two are of how the spot looked once I cut ALL the rust out.

Fourth is the fabricated internal replacement piece. I cut it out of the left over replacement lower quarter panel extension. The two punch holes are where I will put additional spot welds for stability.

Once fabricated I taped it into place so I could size and cut the outer panel replacement piece. (Fifth picture)

[pwogaman]

I fabricated the outer panel replacement piece with a lot of pounding, bending, cutting, welding, filing. The next picture is of the inside of the outer replacement piece. Not pretty, but you will not see it once it is gooped up with seam sealer.

The following one is of the external panel piece taped into place ready for welding. Not so bad looking if I do say so myself.

I will weld it into place tomorrow. Due to a surprising amount of grease between the two panels I do not want to weld it without being able to control an uninteded fire

Excellent work. I shudder to think what I would have turned that into.

[J. R. B.]

Beautiful work. If you didn't live so far away I would let you tackle mine. Believe me I would pay ca$h for your craftsmanship on my car.

[rs899]

Nice work. I repaired much the same thing on the other side on my 240D two years ago. I just glued it all together with two-part epoxy metal bond and the area has held up well.

[Johnhef]

Originally Posted by J. R. B.

If you didn't live so far away I would let you tackle mine.

but me on the other hand, am not that far away. Want to try some of my rust? Its one of the things I am dying to learn how to do.

[J. R. B.]

I would try to fix it myself but I have absolutely no patience when it comes to body work. I can stand all day long in front of a lathe or mill but body work yeech.

[pwogaman]

Here is more of the project.

The first picture is from the outside of the outer piece initially welded in place and the welds ground down

The second picture is of the inside. The welding is not pretty, but who's looking. This area has since been covered with 3M seam sealer. Once the seam sealer cures a couple of days, I'll hit it with some under coating.

Because of a little bit of weld heat warping and imperfect grinding to remove the excess welds, I used a thin film of instant Bondo (in a tube ready to use) to smooth out the shape. Third picture.

The Fourth picture is of the repaired area from within the trunk. This area has already been primed in the picture and has since been coated with 3M seam sealer.

The fifth picture is of the repair area after spraying on some primer.

[pwogaman]

Couple of more pictures to show the fender flare shape.

Oh, by the way - no more rust!

Not too bad for my first time - eh?