Left Hand Wheel Arch Repair Part 2

 Left Hand Wheel Arch - Part 2

So Part 1 concentrated in the Removal of rust and welding in new metal. Part 2 will be about the final prep and painting.

Final Welding prep on outside

First filler of Fiberglass epoxy filler to get all the pinholes

Welded area on inside the battery tray area

Lower sill area spot welded

Closing area at end of sill - Last patch to be fitted

Epoxy filler in panel gap. Will create the line later

Guide coated ready for sanding & filler.

So as the Barn has no facilities for an internal spray booth I had to construct one outside at the rear. Luckily the guys at Bug Barn had a temp garage tent (Thanks Nige)

First sand down of filler and masked ready for Epoxy Primer

First Coat x2 coats of Primer. Bought a new brand of Primer. Much better coverage and finer grade than the Epoxy 121 brand. Also much flatter and easier to sand.

Spent a bit of time applying Glaze filler to get a final flatness before applying top primer coat. Its nice to have filler between 2 coats of epoxy just in case you sand through.

Final sand and mask up again for top coat of Primer.

Last coats increasing the solvents ratio with increasing layers

Cutting in progress

Final flatting and cutting compounds. Stepping down to finer and finer grades each polish. One small overlap area burnt through but quite low down along the sill area. 

Betty is finally home. Lot more cutting and polishing up of layers. Also quite a few overspray on rear and around the rest of the bus.

A few finish up jobs such as the new bumpers. Will Waxoyl and protect once I have time.

Left Hand Wheel Arch Repair Part 1

 Gosh been a little quiet around here. Global pandemic does not help.

Betty has been resting on a new Barn over winter. With Covid restriction not allowing me to visit her until now.

With regular access since April I have started work on the Rear left hand side wheel arch.

The left hand wheel arch has had a small amount of bubbling just above the pressing over the wheel for a many few years. It never looked as bad as the right hand which was done a few years ago. But now was the time to have a good look.

Small amount of rust in two areas

Lower area around sill

Along the top edge

As always it starts with a few rust bubbles and then turns into holes.

Needed to understand why the lower corner where it meets the inner sill was rusting out. A bit more picking and the cause was found.

Under the underseal a hole had grown into a major entry point for all the water

So started to remove the rest of the paint and a good amount of cutting off the old outer wheel arch later.....

Quite a lot worse on the inner tub edge

Caught the rot not to effect the sills much

Gone up quite high

All the way back to the Battery tray. Rear corner and tray look okay

The rust had been a lot worse on the inner wheel rub area on the inside then obvious on the outside

So some inner tub repairs are needed. I always prefer to do these first and work my way outwards. Start with the flat vertical areas and then move onto the outer skin. Then coming back to finish the inner / outer closing lip once both are done. It makes life a lot easier then trying to do inner edge in free air not knowing where the outer is going to end up.

Cut out the inner sill closing

At least the C Post has not been badly affected. Only surface rust.

So much cutting and a lot of rusty metal removed. Nothing I have not done on the other side. After cutting and cleaning back a good coating of FE-123 rust converter was applied to all areas.

Moved onto starting to build up the inner wheel rub.

New straight area at the top was grafted in. New curved area on left created. New angle on right between the tub and the "mud flap" of the tub also built back.

Now I was happy the areas of the tub has been recreated I moved onto the outer skin.

Outer skin cut down to size and trial fitted

Outer body cut to fit

So the repair panel and outer body cut down for a massive long butt joint weld.

Painted all non welded edges with Epoxy mastic paint to ensure the area is good coating.

Coating the whole area again with Weld through primer again to ensure a good seal.

Moved onto the welding.

Tacked and then welded along. Ground down the weld.

I chose to align the butt weld at the top and then move downwards to the sill and battery tray to ensure I had a good panel gap without compromising the flatness of the join at the top.

Clamp the bottom sill on the left. Had to clamp down quite hard to get it to meet the lower sill limp. Poor cheap reproduction pressing. Tacked it in place.

Then moved onto the Battery tray on the right. again had to press in, clamp and tack weld. This allows me to get a good body gap which runs down.

That's all for Part 1. So far I can only have work access on Saturdays. So I did this over 3 days worth of work.

In Part 2 I will conclude the welding and hopefully have it finished. Maybe in 2 weeks time. Might be a part 3 with paintwork.

Stay tuned.