Right Rear Fender Forward Section Rebuild

The inner rocker panel is trimmed to fit. As with the rest of the components on this side there was more salvageable steel than on the drivers side.

 

I punched holes in the top of the existing inner rocker panel, so I could slide the repar panel behind it and weld it in place.

 Final fit...

...and top edge is welded in plce.

 

Now the bottom needs to be tacked in place.

 Some rot in the inner fender needed to be cut out...

 

 ....and replaced.

Once the patches are in place the whole area is ground...

 ..and painted.

Next step is to replace the outer rocker panel. I'm going to reuse the outer rocker panel hat ws removed from beneath the drivers door. Here the panel is held to begin to trim it to fit.

The panel is carefully trimmed, formed and fit several times...

 ...until it fits

The outside paint is ground off and the panel is clamped in place.

I begin to tack the panel in place.

 The final patch is cut, fit and tacked in place.

The welds are ground... 

 The bottom is tack welded...

 

...and the panel is primed.

The passenger's side rocker panel is rebuilt!

 

Right Side Front Fender Rear Section Install

After lining up the outside rocker panel and clamping it in place, I began tack welding the panel to the inner rocker panel

I found the Harbor Freight Spot Welder does an excellent job on lapped panels.

 

The key is to get both panels clamped tightly together.

 

I makes quick work of welding and leves a decent finish

Next I move on the the front fender, rear section that we had to remove to access the door pillar area for restoration.

Initial test fit 

 Fit up after trimming

Used top of replacement panel to determine cut line on existing fender...

...then cut it on the line.

Final fit up, clamped up & ready for welding.

 Tacked...

 ...and welded

The panel had some runs in it from the factory, so I decided to grind off the factory primer and re-prime.

 

Primed...

 ...not bad!

Moving on to the right rear fender front section.

I trimmed the remining section of the rocker panel and began to test fit it.

Done for the day will get back on it tomorrow.

Right Side Outer Rocker Panel Install

Now that all of the interior compnents have been rebuilt and the rockr panl line established, I can begin to install the Outer Rocker Panel sheet metal. 

 

 This side will be rebuilt in sections as there is more "good" existing structural tine left and it will help keeping everything lined up properly. I prepped the area but cutting away all of the old sheet metal and...

....trimmed the replacement piece to fit.

  I punched some holes along the top edge of the rocker panel to facilitate tack welding to the existing inner rocker panel...

 ...set it in place & welded it in.

 

 After cleaning up & grinding.

Next step is to align the bottom of the outer rocker panel with the bottom of the inner rocker panel.

I hope to spot weld this in place tomorrow.