Lower Fender Panel Repair - Rust Reincarnate

The patch follows the form of the fender until we get to the very front portion which has a tighter radius bend. This area will need a little more persuasion to get it to fit perfectly.

To this end, we're using a hammer...

...and dolly to get the panel to the proper shape.

This Craftsman three-piece body and fender dolly set consists of a heel, general purpose, and toe dolly and would cover the majority of repairs one would encounter.

The Key to Metal Bumping has been in circulation for years and the information contained within is just as relevant as when it was first published.

With a little persuasion, the panel is now nice and flush with the fender and follows the shape perfectly.

Intergrip panel clamps work great to maintain a flush relationship between two panels while also leaving a 0.040-inch gap for full weld penetration.

Since the repaired area is where the fender and the running board meet, we thought it a good idea to back up the panel with another sheet of 18-gauge to provide a nice, strong section that will resist damage.

The backup panel is tacked to the fender to stiffen up the lower area.

To roll the edge over and retain the curvature of the fender, four relief cuts were made in the extended area.

Each section was then rolled over individually and then welded up to form a continuous lip.

Here's the surface of the repaired area after the weld has been sanded smooth. Note the rolled edge.

The repaired section is now nice and solid and ready to be mated to the running board once the omitted mounting holes are marked and drilled.