Sheet Metal Repairs Fenders and Doors

Duane WI

Member
Some more pictures of my 52 Chevy pickup restoration. Here are the rear fenders and doors. I made all of the repair panels from 18 gauge sheet metal. Fenders needed front and rear sections replaced and some of the back flange that bolts to the truck box. The doors needed new inside and outside bottoms. I am currently working on the front fenders. My work process is to remove a part and fix the rust. After everything is repaired I reassemble everything to make sure it still fits together. Then take everything apart and do the body filling, sanding and painting.

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I am just getting ready to start doing the same on a 34 dodge truck. I was able to order the needed patch panels and will do the work at the local tech college. I took the night classes back in the 80's to do some body work on a car. This time I get the senior discount and it is cheaper than trying to do it in my shop. + I have an instructor to make sure I'm doing it right.
 
Glennster, I have seen some of your posts showing finished cars you have done. They always look great. I am just an amateur having fun. Leave the really high quality work to professionals.
 

Good work! I just got past that point on my '67 Datsun two seater a year and a half ago. I am working on final smoothing of high build primer coat now. I have had doors on and off many times getting them to come together just right. There were few repair panels available so I had to make my own. Are your welds going to be all continuous when done? or spaced plug welds?
 
Continuous welds. Most of the time I butt weld but on the door skins I used the flange tool. It gave me some wiggle room to adjust the panel fitment. Also adds some more strength in the long weld to reduce any chance of oil canning. I only use the flange tool if the flange opens down. No place for water to collect.
 

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