thought i would show how i am repairing the rust on my rear panels. this was caused by dirt setting in the bottom of the wheel well.

i had to cut the inner and outer fender out

i had to use two pieces and tig weld them for inner fender

here is the replacement sheet metal tacked into place

always use oem sheet metal for patching. i got this from the dealership.


tomorrow i will make the outer piece, and install it. then start the otherfender.

 

looks good

 

this outer patch took me eight hours to build and weld on. sheet metal man i am not. first try at tig in 20 years, and it shows. i just hope the other side goes faster. little grinding and bondo, almost as good as new. the contour is very close to the original lines. wrapping and tucking the bottom is what took for ever. the harbor freight box is blocking the sun for the pic.

 

looks good .. and I'm sure your a handy guy .. but holy crap you could have replaced the whole 1/4's with fiberglass ones almost in that time ... toyotafiberglass.com ... I guess if you have the welder , and have the time ..

 

cool..motivates me to make the patch for my rust hole seen here...

thanks man!

 

the next one will only take a couple of hours tops. i had the wrong size tungsten and filler wire, and i know how to make the the patches now.
i thought about the fiberglass panels, but the money i saved i am going to buy auzzie lockers i am going to coat the inside of the fender well with por15 and fill the cavities with caulk type body filler.

 

That really didn't look all that bad to jstify cutting it all out and welding in a new piece. Was it worse than it looks in the pic?

 

looks good i just did the same thing with mine last week and just put bondo on it today

 

it was pretty bad. the metal has to be like new to tig weld it. the inner fender was really pitted so that is why i cut it out so i would have some good metal to weld the outer fender to. i gained a whole lot of respect for those chop, cut, rebuild guys.