Inner fender panel repalcement - advise

[BroncoMark]

Awhile back I got the bright idea to replace the inner fender panels because they had some rust through in the typical places. I drilled out the spot welds and removed them. I got some new panels from JBG and I'm ready to put them on. I figured I'd mock them up and put the fenders, hood and grill on and get the panels lined up before I weld them into place. I spent an hour messing around with it today and it's not going as smoothly as I had hoped just to get the fenders back on there. Any advise on how to tackle it from those of you who've done it?

 

[BroncoMark]

Added a better pic.

 

[rcmbronc]

What exactly isn't going well. When I replaced my last ones they went pretty smooth. They actually lined up real well with very little trimming required. The tricky part will be where it attaches to the kick panel. Is the steel in this area good? The lower area of the new inner fender follows the wheel tub and the front wraps around the core support. Let us know the exact problems and i can try to help.

 

[rcmbronc]

Some pictures

 

[TJK74]

Well it looks like you have got it pretty well apart. this might be a mod you concider adding in while your at it. Its nice and easy and makes the front clip removable.
http://classicbroncos.com/frontclip.shtml

 

[BroncoMark]

Thanks for the replies. The part that isn't going well seems to be just getting the placement of the new panel just right so that the fender bolts up flush. I had a hard time getting the holes on the back of the fender at the door post lined up. The fender needed to come down a bit but was already down against the top of the inner fender panel. It's hard to explain in words. I'm going to spend some more time on it tonight. I thinks it's just a matter of moving things around and possibly some trimming. Do you guys recommend test fitting the fenders, hood and grill for alignment before tacking in the inner fenders or is getting the fenders lined up close enough?

The metal at the kick panel is in decent shape. There is some pitting on the inside area, but it's solid enough to weld the new piece onto.

 

[rcmbronc]

It would not hurt to try to align the fender and hood. I did not, but it would be best to double check. With the body on the frame like you have it, the core support and door post cant move, so as long as you can install the fender and it meets the core support and door post fine, it should be OK.

 

[BroncoMark]

With everyone's inspiration, I got the drivers side just about done last night. I got it lined up and clamped in place. I welded the back section to the kick panel where I had drilled out the previous spot welds. I may be able to borrow a spot welder, so I'm holding off on doing the rest for now. I'm going to tackle the other side tomorrow. ;D

 

[TJK74]

Good Job! Keep us posted with some progress pics as you go;D

 

[BroncoMark]

Hopefully I'll remember to bring my camera tomorrow.;D