Inner Fender Rust Repair Help

[Ol'Blue]

Front inner fender on passenger side has a small patch of rust. Looks like its only the inner layer of sheet metal, outer layer just has surface rust.

Should I just cut out the outer layer and weld in a patch or cut out both layers. Inner layer is surprisingly thin.

Thoughts?

 

[MonsterBIlly]

I removed the entire panel and replaced it. I had never done work like that before. It was not too hard. just took a little time and some reading. after I did the drivers side, i went ahead and did the passenger side too.

they are layered right where the rust is. I dont think you need to do the entire panel, you can just get piece of 16g sheet metal and do a patch.

 

[Timmy390]

Very common. I had to replace both sides. I made patch panels and welded them in.

Tim

 

[langester]

Every patch panel I have ever done, I started small and cut until the rust was completely gone. Some times rust creeps between the panels and you really cant see how bad it is until you dive in. Most of the time I ended up cutting more than I planned. At least that area is in an easy access area compared to some.
Good luck with it!

 

[Ol'Blue]

Thanks, I have to remove the outer fender anyways to replace the broken air box so I may as well get in there and make sure to get it all.

Tim, just to make sure you replaced the two thin layers with one heavier gauge sheet?

clean work by the way.

 

[Timmy390]

Tim, just to make sure you replaced the two thin layers with one heavier gauge sheet?

clean work by the way.

Thanks.....I added the inner and then the outer. 2 layers total. You can see in the picture if you look close I cut the inner and outer just a bit different so as to have something to weld to. I also drilled a few hols in the outer and plug welded it to the inner and ten seam sealed it all up

Fist pic is the inner tacked into place......Second is the outer clamped into place....Third is all done

Tim

 

[Ol'Blue]

Thanks.....I added the inner and then the outer. 2 layers total. You can see in the picture if you look close I cut the inner and outer just a bit different so as to have something to weld to. I also drilled a few hols in the outer and plug welded it to the inner and ten seam sealed it all up

Fist pic is the inner tacked into place......Second is the outer clamped into place....Third is all done

Tim

Got it, and used the drill bit to cut out the tack welds to separate the two pieces.

 

[Timmy390]

Got it, and used the drill bit to cut out the tack welds to separate the two pieces.

I use the super cheap spot weld cutters from Harbor Freight.
https://www.harborfreight.com/38-in-Double-Sided-Rotary-Spot-Weld-Cutter-63657.html

They CUT through about anything like butter.........

Tim

 

[Ol'Blue]

I use the super cheap spot weld cutters from Harbor Freight.
https://www.harborfreight.com/38-in-Double-Sided-Rotary-Spot-Weld-Cutter-63657.html

They CUT through about anything like butter.........

Tim

Yup, I bought a nice one for about $20 and the HB did almost as well for less then half the price. I think I went through three cutting the floors out.