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  #1  
Old 09-25-2013, 09:06 PM
Simple guy Simple guy is offline
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Default My Wheel Arch Repair.

Let's start this off with I am a tech not a body guy. I have no training in body or metal work. This is how I personally with my own thought processes have figured to repair my rusted through wheel wells. I have concluded that the space between the inner fender and the bedside is too small therefore collecting dirt, sand, mud, water and road salt. This sits and leads to the massive rust holes I had. I decided to not use preformed patch panels which would leave me setup for the same outcome. I will say that these had previously been repaired with patch panels by a previous owner. I bought flat aluminized steel from Eastwood and cut/shaped my own fenders to make a wider drainage channel. The point of this is entire repair is function over form, I do not have a show truck.


Both sides were packed with sand, mud, dirt and was fairly wet even though it hasn't been driven in rain for weeks.



I used a ball peen hammer and a screw driver to assess the rust damage. I realized at this point you can see fiberglass on the inner fender. I know these had been repaired with preformed patch panels because someone did a crappy bondo/sanding/paint job.



I used a ball peen hammer and a screw driver to assess the rust damage.



Driverside cutout and wire wheeled. Notice the gaping hole in the inner fender that will be patched.



This is the passenger side cut out and wire wheeled all of the rust.



This is a piece of wheel arch formed. The plastidip is sprayed to mark the line to cut.



This is the driverside wheel arch ready to be tack welded and final fitment/forming


I will update tomorrow after welding with pictures of plug welded backer plates and my fabbed panels, figured I'd start this or I'd have too many pictures to upload and wouldn't feel like doing it.
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Old 09-25-2013, 09:16 PM
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Pretty cool. Keep us posted.
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Old 09-26-2013, 10:04 PM
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Driver's side is welded in. Half the passenger side is welded. I just have to finish the passenger side and get a new grinding wheel to grind down the welds then body filler everything. Might be a while until it's finished though. I have back surgery coming up soon so I'll be bed ridden for awhile.


This is my friend welding
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Old 10-02-2013, 08:55 PM
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Update, Today I started body filler. final layer on the driver's side is curing now, I will sand it out to 180 and shoot primer. I will take pics tomorrow. My phone died listening to music :/
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Old 10-03-2013, 07:21 PM
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This took me 4 coats of body filler, 3 coats glazing putty. This is as far as I'm going to get before my back surgery has me bed ridden unless I get the passenger side welded within the next 2-3 days. Primer just needs to be sanded and one more coat then maybe rattle can color match paint.

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Old 10-03-2013, 08:26 PM
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Wow that repair looks great. A little paint and that side is all ready to go!
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Old 10-03-2013, 08:50 PM
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thanks, the wheel arch isn't perfectly rounded but i'm throwing on some fender flares. So it should hide it.
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Old 11-27-2013, 10:33 PM
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Well, sorry this hasn't been updated I had spine surgery back in October and haven't been able to get anywhere with this. Now it's too cold to even mix the bondo. when ever i make some progress I'll post it up.
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