Lower Rear Panel Repair

I started to create a custom repair for the rear panel. After cleaning all the old paint and filler I measured and the rust was 99% contained within a 5cms width gap. 

I made the decision to make a 80cms strip that would be welded in place after cutting out the rusted area. I will make separate repairs for each section under the rear lights housing later on.

 

I really enjoy shaping the metal to fit.

Rear Panel Inspection

The rear panel has two main damages areas. The first is where is is connected to the boot floor as you can see from the photos below.

The second is the damage to the offside (right) rear lights housing which is pointing inwards.

The only option I could see was to cut the rear panel away from the rear lights housing.

That allowed me to persuade (bang with the hammer) the lights housing to go back more or less inline to its original position.

I will need to spend a lot more time to get this right but for now I am happy that I am confident I can restore this panel back to its original shape which is necessary to get the new floor in place.

Inner Rear Wheel Arch Repair

A new section brings new challenges. The wheel arch has a nice little curve to it that I suppose is designed to allow the water and mud to flow away. 

Obviously not quick enough in my example...

So a custom repair is needed as a new panel seems more than I require, which I suppose is a positive. It gave me another chance to create a custom panel that I love making up.

First create the templates.

Then cut and shape the metal.

Weld it all together.

Looks good so far!

A rather rusty bottom

The title says it all really...

   

Must keep positive

 

Oh it's more like a horror movie

Think I need some more panels!!

Outer rear wing inspection

In order to start removing the patch welding from the Midget's boot floor I need to check the outer rear wing as I suspected that the inner wing repair was attached to the outer wing panel.

I knew there was some filler behind that paint! This explains why this section of the wing bends inwards that I will need to straighten somehow. I would think some sort of reversing mishap or a shunt from behind? Who knows

I have to say that I am quite relieved that this is the extent of the damage to the outer wing. I had imagined the filler and holes to be much higher than this. It will be much easier to retain the original shape.

Boot floor inspection

I can't believe I am actually writing this, but yes I have started to work on another section of the car... the boot!! (or trunk for my American followers)

This is a particularly challenging area of the car, so I will need to take my time. Certainly on the right hand side where some of the worst rust damage can be seen.

You can see some of the damage from underneath as well as from the top.

There was so many botched repairs that will make it harder to work out where the new metal should go. Speaking of new metal, I picked up the new panel from Moss, which is the biggest panel I'll have to weld in.

I have taken the decision to replace the whole floor. I just don't see the point trying to restore such a damaged section. So over the next few weeks I will be removing the patch panels and cutting out the rust and making way for this new panel. I seem to remember I will need to do a lot of spot weld drilling! Which reminds me I need to buy a new set of spot weld drills as mine are blunt!