Im trying to get my classic 1980 BMW sedan reregistered. a Problem it has is rust in the front fender and sill which the inspector said is not allowed.
One of the issues with this car - and all my others actually - is rust about the front fenders, at the sill level - this is where road muck gets caught against the inner wheel well liner, creating a nice spot for this muck to accumulate, and with constant wetting eventually it causes rust from the inside out to the fender.
If you are smart enough to catch it + clean out the inner liner, then you can prevent the sill corner from rusting too.
Well I took the fender off today ( Right side)
and lucky me the sill corner has signs of rust

so I wire brushed, grinded and sanded the surface to see how bad it was. - its got holes


I also attacked the fender with the abrasives to see how bad it is.

I suppose its not too bad, maybe a bit of metal patching is all it needs

nope - back side is very rusty and part of the support fame has completely gone

I have another fender thats got a reasonable support pieces, so I'l take a template off to make a duplicate.
Im wondering , to a make a new section for the sill, if a flexible shape pattern maybe the way to go?
I re watched Wray Shelins you tube video on it , and had a go
Metal Fabrication: How to make a Flexible Shape Pattern and Gauges by Wray Schelin's ProShaper Workshop
"https://www.youtube.com/embed/y-JQgPm4_7s"
One of the issues with this car - and all my others actually - is rust about the front fenders, at the sill level - this is where road muck gets caught against the inner wheel well liner, creating a nice spot for this muck to accumulate, and with constant wetting eventually it causes rust from the inside out to the fender.
If you are smart enough to catch it + clean out the inner liner, then you can prevent the sill corner from rusting too.
Well I took the fender off today ( Right side)
and lucky me the sill corner has signs of rust

so I wire brushed, grinded and sanded the surface to see how bad it was. - its got holes


I also attacked the fender with the abrasives to see how bad it is.

I suppose its not too bad, maybe a bit of metal patching is all it needs

nope - back side is very rusty and part of the support fame has completely gone

I have another fender thats got a reasonable support pieces, so I'l take a template off to make a duplicate.
Im wondering , to a make a new section for the sill, if a flexible shape pattern maybe the way to go?
I re watched Wray Shelins you tube video on it , and had a go
Metal Fabrication: How to make a Flexible Shape Pattern and Gauges by Wray Schelin's ProShaper Workshop
"https://www.youtube.com/embed/y-JQgPm4_7s"
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