It's going slow, but progress. After finally rebuilding the inner fender wells, I'm finally feel like something is getting done. The replacement panel doesn't have a cutout for the fuel door, and I'm not sure how I'm going to do that. I don't think I can neatly bend over a flange to fit the fuel door opening,but not sure. At this point, I'm leaning towards cutting it out the same size as the opening, then welding a strip to it to go inside the opening. Anybody done this and have any suggestions?

Thanks in advance,
Chuck

 

nice work keep it up buddy

 

Anybody ever install the Wolf panels? The fuel opening isn't cut out with the 'flange' like the old panel. I'm leaning towards cutting it out the same size as the opening, then welding a strip from the inside of the panel to wrap around the opening, and attaching that to the inner panel. I'm a HVAC guy, not a body man. Any input from someone who has done this would be greatly appreciated.

 

Damion812 did some rust repairs around the fuel opening:
https://www.yotatech.com/forums/f115...l#post52479735

 

Thanks for pointing that out. I skimmed through that post, but missed the fuel door thing.

 

No experience painting so I have lots of primer sanding to do. Also more fill work, but nothing will be too thick. I had to get primer on it before I wanted to due to damp conditions. I did turn up the air pressure a little and tuned down the paint and that seemed to help. Next, I plan to mist it with dark primer and block sand to find the imperfections. No matter what, it'll look better than it did.
I screwed up my bodyline on it and I doubt I'll be able to get that back. I have all fall and winter though, so I'll try.

 

It looks like I figured out how I'm going to get around the fuel door opening. I pounded out this piece. I plan to countersink the new panel with my flange tool, then cut the edges to fit in the countersunk part. I'll probably make another. I used pine wood I had laying around and it broke midway through the job leaving it a little sloppy. I'm only going halfway up the opening to stay away from the bodyline that runs along the top of the fuel fill opening. I'm somewhat confident this will work and it also give me a little play if things don't line up perfectly like they never do for me.

 

I like what you’re doing. I was in the same position, doing my own body and paint work a couple years ago. See my thread. Thankfully mine did not have much rust. Just some previous bad bodywork to correct.Buy good sandpaper and block the primer real good. Run a piece of tape along the bodyline and block down to it. Then move the tape and block sand up to it.

 

ha ha I was following here to see what's done 😆

I tore into the fuel door section not knowing how it was originally there is a seal or seam sealer in this and it a double wall thing. That panel you made looks good! I need to do them wheel well panels next.

 

Mine appeared to have remnants of panel adhesive on it. As soon as I drilled the spot welds, the panel popped loose. I plan on more panel adhesive and 3 pop rivets. I have work cut out for me.

 

I haven't had much time lately to put into the project, but it is moving along. So much trimming and fitting. I also suck at laying down body filler, but it's getting done.

 

It looks pretty damn good to me!

 

To me too!

 

Thanks for the encouragement. Here's another smaller fix.

 

I used to deliver parts to Sam Foose, chip Foose's dad. He ran a conventional body shop to pay the bills, but his true love was custom jobs. One day he was showing me a 50's era Ford he was building for a client, and was in search of a fender. "what if you can't find one?", i asked.
"Then we'll just make one" was his quick reply.
And he did. Just hammered one out.
That's the irony of beautiful body work. If you don't notice it then it was perfectly done.

Nice work.

 

Been bending ductwork instead of bodywork lately, but I did manage to get the bodyline somewhat straightened out and an inner and outer door patch. I made some sanding blocks out of a paint stir stick that helped greatly. Time to start of the dreaded tailgate next, but I don't think it will be as bad as getting that bodyline back.

 

Nice! I have those same sanding blocks. Good stuff.

 

The Durablocks? Me too. Thankfully I haven't seen them since 2016. I'm getting PTSD looking at this page. I wouldn't want to relive it all.

 

yes, the Durablocks are great. For me, this thread makes me remember how much i enjoyed doing my bodywork and paint. Really. Need a new project vehicle.😁

 

I'll be starting on the tailgate this weekend. Hopefully these posts will help others attempting this. If I could start over again, I think I'd go the fiberglass route. I bought this 4runner 20 years ago for $100. It's been a great daily driver/work truck. It's almost like part of the family.