So a few weeks ago I discovered the body rot in the passenger side fender apron, and since then I've been pondering what to do about it, the options being:
1. roughly weld a piece of metal over the holes.
2. patch the panel using part of a replacement apron.
3. drill/cut out the entire panel and replace it.
Well, option one is tempting in a way because it would be quick and nobody's ever going to see it anyway, but I'm trying to do a good job with this project...and the disadvantage of option three is that I'll lose the VIN number - unless I graft it into the new panel - so I thought I'd have a go at option two. I started by cutting out a large chunk of the metal around the damaged areas - I made the cuts in areas where the panel was roughly flat to make the welding easier. The replacement panel I got was, just by chance, sold by
Dynacorn - and it was a very good fit. Apart from trimming up to fit the opening, I barely had to finish the patch at all.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMWv-ThMEixx9peaqgQjStbCHh2XxK13VhuxNURYgX9OzPiPlg1WYVEwBUdCU99wGswf-qrt9A2iBb58BdFGRC4mEVzMLrxL8tYzQPG_nmL2mazk9nDb0rDxgbGY2c-ZqIC0RhjIvjFXk/s320/20110803_mustang_113a+%255B800x600%255D.JPG) |
Dynacorn replacement body panel |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrPO_LwFXsjNrZskqWBeoLY4zw_Knc9gWXk-PY3HlLwgOHF1brx0l1sjRu4BMgGW3DfgrAvGUefE_fx-UrsXEpeIGWXKCi6GkYXOtmR6vdpHJ33ERwkrvsb8MY9EtJ7bvNahA-3cLp4bM/s320/20110803_mustang_119+%255B800x600%255D.JPG) |
Got the patch set in place with minimum fuss |
This is where things started to go wrong. I tried lots of different settings on my welder, and I tried a huge piece of copper as a heat sink, but whatever I tried, it all ended in holes: lots of holes burned through the metal. My progress as a welder has been helped along A LOT by a lesson from my friend Abe, but I still have a long way to go. I actually finished up welding in the entire patch, just for practice, but before I was even halfway done, I knew I'd be cutting it out again.
So I a few days later, and I went over to
RPS to pick up another fender apron...only they were unfortunately out of stock...this was a pain because I wanted the new apron in time for the weekend, but there are other parts stores close by so I tried calling a couple...eventually I called up
Mostly Mustangs in Oakland - their main business is repairs and modifications so they don't really sell parts, but they did have the right apron on hand and I made a deal which included the owner letting my into the shop after hours. So I had my new panel before the weekend....but hold on, not so fast. I didn't really look at the panel when I picked it up - I was too busy trying to keep my son away from the M&M's dispenser in the
Mostly Mustangs office - but when I examined it the next day I realized it wasn't a Dynacorn panel (if I'm honest, the "Scott Drake" sticker was a bit of a giveaway). Still unconcerned, I cut out the old panel and my awful patch, and then tried the new panel for fit...and man, it was soooo bad. I couldn't bring myself to even measure how far away it was. Instead I called up RPS, ordered another Dynacorn panel, and went to work on a different part of the car...a week or so later and work continued.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgblhMPnTgTvyDvSoTxvg5XC8cGfSV46x44YbHl643VSpaLPKAU7yAnNFqavqzRMH0s9S4hUhmzAQcDd2tS9mSCq5qLb0RFKlyRAoUHLhT85lF9uDlquV4PvfW31gdQMxHMzZ_iKoM_xdY/s320/20110813_mustang_161a+%255B800x600%255D.JPG) |
I was disappointed by the amount of rust between panels - elsewhere on the car I can't get at it, and I don't like that at all! |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyGsc8ynypFzIStGcHwQwuGt8VkrnsN_IxWyjQPPB4Fc9G0Sc8-DqZymdEmisOMniBhmza1TgWjwnQU4TJLoTfbo0fIPbXAMITBVb-EMcLmoqmJ9BD90vx-mMLTIehKpOIpMEGtUMPrAY/s320/20110813_mustang_168+%255B800x600%255D.JPG) |
Sprayed on some Zero Rust where the panels will overlap...shame Ford didn't! |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-yVlWRnVE3YHA1uJzsggt0U2jrpvlhg4hn0hyphenhyphenu2TGZmzqBWAKVHyRhmRU-RRnXLzlY0mpIUOcUUS8WYZXM3eTx29PyvxzU_Qryqn-rIemW9Tj9BQzRbLVUmBI7NkV6u5qP7xuKXhUte8/s320/20110813_mustang_171+%255B800x600%255D.JPG) |
Clamped, bolted and sheet-metal-screwed into place after minimal adjustment. |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihHiqHaHzN9izrgcS6VdK3OnO2ERTlAkcxYqVSv4Jl3RzGIapxauYAwCnlPvkMRyUyK4sijMp_AwWVQRnV8P5vyq02MNczsns6OIO7C6Sqlx2qK_SWBrUzWnlWsbYrnMzPh3tcSHtMcyY/s320/20110814_mustang_180+%255B800x600%255D.JPG) |
Spot welded the new metal into place. |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgizRG4qiktfQNTRCWaCNbCanZ23XEFt8fVs50UPdp1r9EPI4f-dSIKZvOcai12RV4-nJpOorSiAv-P009Gw11WuaWCEDHyd1d-Rblrxx8rgSaaDFQmWgx1Dg9CTIu9GHJtkFJHz3B7T0Y/s320/20110814_mustang_185+%255B800x600%255D.JPG) |
All cleaned up..should have done it this way the first time. |