Now that the rocker panel structure under the driver's door had been replaced it's time to begin to restore the panels removed for access to the rocker panel.
The front section of the left rear fender had been previously replaced. It was not fit in well and will need to be adjusted.
The panel is laid in...
I'm also not planning on re-installing the jack points, so I don't need the cut outs.
I have the "old"outer rocker panels that I'd removed and replaced with new panels. They're relatively straight and in good condition. I'll use the bottom edge to extend the fender panel the 3/8" I need.
I also trimmed the bottom of the fender panel to accept the new piece.
I position the two pieces to mark them to size.
The new bottom lip tin is marked to be rough cut.
...and the fender panel is maked for fit.
The fender panel trimmed and checked for fit.
The bottom lip is clamped in place and marked to be cut to the finished size needed...
Next step is fitting the two pieces together. I begin by grinding off all of the pain from the surfaces that will be welded together.
Next, I clamp the pieces up to begin tack welding
From experience, the panels will be more flat after welding if you leave a slight gap between them when tack welding. Harbor Freight sell some spacing clamps that are inexpensive and work well.
Once the gap has been established with some tack welds, the spacers are removed. This allows me to get some copper backing plates on the backside of the panel. The plates I'm using are approx. 3/16" thick & 2" wide. They act as heat sinks when welding and the weld doesn't stick to the copper. The clamps and copper plates make tacking the panels together easier!
The initial pass of tack welding is ground down ...
...and any voids in the weld are identified & filled on the second pass.
After a complete outside surface sanding the panel is tried for fit.
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