Episode 22 (May 22 - May 28)
 
 

Things went fairly smoothly this week. I had a couple of evenings free, so I was able to get to things. I've found that if I concentrate on fitting one single piece at a time that I am able to fit it much easier than trying to put all on at once. I'm also learning that original German parts fit much better than cheaper Brazilian parts. Live and learn.

 Back to The Rear

Both doors now close properly, so it's time to continue my way to the back of the car. In this picture, you can see the new piece (black) is bolted into the rear wheelwell before being welded for good.
 

 

 
 

The Fasteners

I use small nuts and bolts as well as these self tapping screws. I use my cordless drill to put these little guys into the sheet metal. They hold really tight and the hole they will leave when I finally remove them fills easily with the mig welder. 

Inside the Wheel Well

From the inside, you can see that I have made use of every landmark I can find to insure a proper fit. The new piece is bolted to the frame and to the existing body. 
 

 

  Another Step Backwards

I had to remove the lower quarter panel as I had earlier installed it incorrectly. This particular piece has a nice lip on it for easier positioning. I had to trim a fair bit more of the body to make it fit properly.

 Back in Place

Once I had it dry-fitted into place, I tacked the panel onto the car with the mig welder. I then put the rear fender on to make sure everything was in line. The first fit was pretty close, a bit of monkeying around should tighten things up nicely. 
 

 
 

 Strength from Within

...on the car that is! I welded in some body metal to join the heater box to the body. The door closes even better now. Notice on this interior view that you can see the clean edge of the lower quarter panel from the last photo. 

 More Fitting

This whole process is kind of a chicken and egg thing. You've got to put things on in the right order and make sure that future pieces will fit when the time comes. I put the rear fender on to test the fit of the new quarter panel. It became obvious that there was a bit of 'freedom' to the fit of the fender so I ultimately had to fit the running board.
 

 

 
 

 Not Bad....

....but I think I can do better! The fender / running board fit is not a critical one. Thankfully there is a bit of play and the joint is more or less hidden. The new quarter panel doesn't follow the fender just right, so I'm likely going to have to adjust it.

 Fender Beading

Where the fenders bolt onto the body, there is a visible gap between the two pieces. This seam is filled with a fender bead which bolts in between the body parts and hides the seam nicely. I've been using a short piece of the old beading to check the fit.
   

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