Patch panels were made for the non visual areas that needed help. The material used is left over refrigerator door stock from my prior employer, Whirlpool, which we rcd from Evansville Sheet Metal:
Even did a little "CAD" or "Cardboard Aided Design" to make the inner fender patch panels. This type of CAD is a frequent reference in the Project Binky series of You Tube videos, which I highly recommend. Here's a series of pictures of the repair on the driver's side inner fender. First the as rcd picture:
CAD design of part to cover the rot:
Patch panel in place after automotive adhesive and pop rivets:
Here's a picture of the automotive adhesive we are using:
After application of POR15 antirust paint:
Finally, after initial spraying of undercoating, hard to even find the repairs:
We think this turns out pretty darn well, completely hidden after the final coat of undercoating.
Meantime Ray has been having fun with the body filler. We are using fiberglass filled body filler for the deeper areas, then regular filler after getting pretty smooth. Before any filler we used the hammer and dolly set to get the panels as flat as possible. Here's a series of pictures for the rear area under the trunk lid. First is after removal of all paint and prior body filler:
Next picture is after hammer work plus using a bottle jack to push the area back around the fuel filler neck, had to move it out about 3/4 inch:
Caught Ray in action working the body filler, he's doing a fine job:
We've minimized the thickness of all body filler:
Later this week we have our friend Nick coming by with his welder. We've got the right rear wheel arch panel ready to harvest from our half car:
And we got donated a left rear fender patch panel that will provide at least it's rear wheel arch, maybe more:
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