64V2488 Rehabilitation- 01 Oct 2001
The rusted piece in the outer panel has to be replaced....
Using the air powered panel cutter, the bad piece was excised from the fender
The hydrochloric acid bath derusted most of the corrosion, but up inside the bend was hard packed crust. Holes were drilled to access the rust, more acid and it was finally clean
Even the support behind the skin was corroded, so the bad section here was also cut out for repair
Some cardboard is good to make a pattern, outlining from behind
Using 16 gauge CRS for the insert
Actually it was cut out with the Sawz-all. That's a great tool. Use a shot bag to massage the piece to the correct curve
After some precise grinding, the piece fits right into the opening. Tack weld will hold it in place initially to prevent warpage.
Next the panel piece.....