

Ok, here we go again. This was easier in that I had a little experience now
but harder because it was a bigger panel. I had pretty much an entire quarter
panel but didn't dare tackle anything that large and involved. After
all of the filler and paint was removed, I got a good look at exactly what was
damaged. I chose this pattern because it preserved the undamaged lines
of the panel while allowing me to "hide" almost half of the repaired area seams.
This time, I cut out the damaged area on the body, using pneumatic scissors
on the flat sheetmetal areas and drilling out the spot welds everywhere else
with a spot weld bit. This bit cuts out a plug around the weld but doesn't
go through both pieces of metal. A cutting wheel was only used where
the scissors couldn't reach to reduce any possible warping.
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Once the old piece was removed, more damage was revealed. The inner wheel well
had been pushed in real hard and all of this metal going one way pulled the
rear door post back a good bit. A little hammer and dolly work got both
areas back to where they should be. No rust though, which is a good thing.
Now the patch panel was test fitted, marked, trimmed and repeated several times until the patch matched the body opening. .
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I painted the rocker, inner fender, inner door post and the back of the patch with
the rust encapsulator paint. Then the adhesive was applied and the panel
was put in place. Several holes were drilled for rivets, but not nearly
as many as the rear panel. I just needed to hold a couple of areas together
for the epoxy to set. Everything was glued except the area where the
rocker meets the patch and the very bottom inch or so of the trailing bottom edge
of the wheel well opening. I welded these areas. In all, it matched
up real well and I look forward to finishing up the body work here. NEW!!
Well, the body work was more of a pain than I expected. It finally
came together and the finished product is seamless. Mark it as done!!!
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