64V2488 Rehabilitation
12 October 2001
The manufacturing process on large parts of cars involved
wrapping the edge of the outer skin around an underlying support structure. On
the rear edge of the front fenders and the front, rear and bottom
edges of the doors, moisture will cause a corrosion situation over
a period of time. The corrosion, although not being damaging enough
to break through the skin, will expand the edge of the part giving
a rounded effect.
After the panel is repaired, the treatment is to brush phosphoric acid into the
cavity from inside the panel to dissolve any rust and coat the surface with zinc
phosphate to prevent further deterioration. It can be painted with POR-15 as
a final measure.
The leading edge of our door also had a depression area ( 18") which was filled
and had to be removed. There was also a dent in the styling crease about
4 inches toward the rear. The pictures show the progress over a period
of sessions in removing the dents. A black guide coat is sprayed after
every movement of the dollies behind the door skin. Three tools had to
be made to accomplish the job. It took about 5-6 hours total to complete.
This is where it started. You can see the filler in the depression You can finally see some progress here, as the filler dissappears raising the depression
Almost gone at this point
This 'look' is a tell-tale sign that the part is in a compromised
state, and can be seen even on 'restored cars', even though they
look like a million bucks. The true lines of the panels are a flat
continuation from piece to piece without the dip inward and rise
outward on the second. You can rid the part of this problem by
making a few simple tools out of heavy gauge sheet metal. Required
mainly, is a gradually shaved piece (wedge) to be inserted from behind
the skin and worked up to the edge of the part. Using light peening
blows of a flat hammer on the outside of the piece, that expanded area
can be flattened by pulverizing the corrosion as you progress. 
Start ....
...Finish...
By now the panel had to have been raised and peened back at least a dozen times.