A cars fenders are among its most abused parts. Small rocks and road dirt, not to mention the road salt that eats away at them all winter long, continually assault the paint on the fenders wheel openings. Over time, this abuse will eventually expose bare metal and lead to rust. Rust is metals natural enemy, and will eat away the fenders metal before you know it. Fear not: Cutting out the rusted portion and replacing it with a metal patch panel can save that fender.
Instructions
- 1
Identify the entire area to be repaired by grinding the damaged fender section down to bare metal to ensure all rust is exposed. Be sure to wear safety glasses and ear protection before beginning any work on the car.
2Draw a line around the area of the fender that needs to be replaced by using a permanent marker. Keep as many of the lines straight as possible. Straight lines make fitting the patch panels much easier. Large sections are easier to replace than multiple smaller sections, so include as much damage in one patch panel area as possible.
3Cut out the repair area along the marked lines by using a grinder. The section of metal being cut out will be used to make a template for the patch panel, so make sure it remains in one piece.
4Place the cut-out metal section onto a piece of posterboard, and trace it by using a marker. If portions of the metal are missing due to rust, compensate for the missing areas.
5Cut out the posterboard template by using scissors. Fit the template to the area of the fender being repaired. Trim the poster board to fit the cut-out section.
6Trace the template onto the metal patch panel by using a marker. Cut out the panel by using a pair of tin snips or a grinder. Each patch is different, so choose the tool best suited for the shape.
7Fit the patch panel to the fender. Depending on the access to the repair area, clamp the patch in place by using welding clamps or panel clamps. Strong welding magnets can be used in place of clamps.
8Place a tack weld in each corner of the patch by using a MIG welder. Place tack welds along each side of the patch, about an inch apart.
9Secure the patch to the fender by using inch-long stitch welds. To prevent the panel from warping due to excess heat, alternate sides with each weld. This process may take some time to complete, but being patient will ensure a better-looking repair.
10Once the welding is done, grind down the welds to leave a smooth surface on the repaired area. Use a hammer and dolly to straighten any imperfections remaining on the repaired area.
