Lower Rear Panel Repair Continued

Tonight I continued to work on the rear panel and shaping the custom replacement panels. Having the new boot floor panel really helps me work out the angles and gaps needed to get a good finish.

I have found that plasterers tape is very good for marking out the cutting area as the square mesh helps me see if I am cutting straight or not.

Test fitting is so important, but it looks ok. I had to make a flange at the bottom to ensure it welds correctly on to the boot floor panel.

A few tack welds to keep it in place

Hopefully get the other half in Thursday night.

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!!