Episode 24 (Aug 5 -September 25)
 
 

And the bodywork continues. I find that doing the driver's side is going much faster than the passenger's side, there is no doubt that there is a learning curve to this project. When I started this episode, the hot weather here was almost unbearable, the shop is air conditioned, but the electrical service in my shop can't run the A/C, welder and the air compressor all at once. It is now fall and the cooler weather makes going to work a pleasure.

 Alignment Problem

 

After I positioned the left wheel well, I noticed that the body mount could not line up. After close examination, I have to conclude that the body mount was spotwelded into the wrong position by the manufacturer. It appears to be easier to have a spacer made to make things right than to reposition the mount.
 

 

New Panel

Experience really does seem to be on my side. I easily positioned this fender panel in about an hour. I still have much of the wiring in position, but it will all be coming out soon when the bodywork begins.

Inside Joint

This particular replacement part fit in very nicely. I know you see lots of rust under here, but the metal underneath is fairly solid. I'll take the wire brush and sandblaster to it later. I'm sure it will come up nice and clean.
 

 

  Driver Side Rear Panel

Learning from the other side, I decided it weas best to use as much of the original sheet metal as possible. I did some preliminary cutting and cleaning before removing the entire panel. The original factory creases and bends are much nicer than on the replacement parts.

 Solid Metal

I took the wire brush to the inner wheel well to check the metal. Once all the paint and crap was removed, I was pleased to find nice solid steel beneath. This steel is easily thick enough to weld to, so the first hurdle has been cleared.
 

 

 Tight Quarters

When I switch from one side to the other, I actually move the car against the opposite wall to give me some work room. Since the car rolls and the weather is nice, I can push the car outside and reposition it by myself.

 Lower Panel

The metal on the drivers side is in pretty good shape. I decided it would be easier to keep the replacement panel as small as possible for later body work.
 

 

On the Inside

The inner metal was completely rusted away. I will have to completely rebuild it in order to strengthen the side of the car. Hopefully the repairs will be under carpeting because I know right now it won't be pretty.

First Steps

I start the reconstruction slowly and carefully. I am using the passengers side as a pattern and I think everything will be fine once I get the welder going. The first few pieces were the hardest, everything else should be fairly straight forward.
 

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