So, with the installation of the refurbished front bumper, I had thought that all I had left to do was to feather some damaged paint on the front driver's side fender eyebrow and go through the set of steps prerequisite to repainting it.
Yeah, right.......................................................
So what you are seeing here is the first two of three patch panels that I had to fabricate to repair the inner shoulder of the fender. As it turned out, when I went to strip the fender of its rust, the whole eyebrow from around the 9 oclock position up to around 12 oclock literally disintegrated as well. With that gone, I could see that the rust had eaten away the connection between the fender's infrastucture as far in as the ears that accept the bolts that marry the inner fender well to the fender proper.
The three basic choices were, almost as always, do nothing, repair the damage, or replace the entire fender assembly, both innie and outie. Option three has two sub choices; new or used. Used is available to me but three weeks before it can be acquired and new is around 200 $$$CAD.
So I went with a hybrid. On an immediate basis, due to time and budget, repair what could be repaired. At the same time, put in a work order for the replacement fender at the yard, with the caveat that no one would know for sure if it was useable until it was removed. I may end up out in the daisies doing a lot of the initial bolt removal to facilitate that process myself. You pretty much have to remove the whole front fascia to gain access to the front bolts; fortunately the donor has had this already done to it.
Apres a little time spent dressing and surfacing down all the tacks and plug welds and seams. If it still seems to look a little rough and unfinished, well that is where I elected to leave it. Remember that this is an inner surface and the only way it will ever be scrutinized by the eyes of the beholder again is if I elect to re-open this can of worms and go for a total eyebrow replacement. That is not an economical course of action. as it would require the fender to be dismounted and put on the welding bench for some serious surgery that I have no enthusiasm for performing.
Finally, just a mock up of the outer eyebrow. It still needs some shaping and the pie cuts that had to be made to tweak the curves have to be fixed by tacks and then filled prior to the final install. As it presently sits what I would get is a lap joint along the perimeter. My alternative is to butt weld the entire seam and to that end I plan to scribe the resident body metal to see what more needs to be removed. My concern is that the cancer extends further and deeper into the eyebrow that is currently exposed. Too thin a recipient edge or surface and all you get is blowout.
While not posted at this point, the inner surfaces have already been given three or four heavy coats of antirust black. That is being allowed to dry for the day before the outer panel gets set in place.
The current temperature locally is somewhere between the middle 80's and low 90's with a high humidex. As a personal precaution my Shop time is being limited to 2-3 hours max, mainly because, after the first hour, it is raining so bad inside my clothes that I am soaked to the skin and have to frequently quit for a minute to go find a towel. All the water on the floor yesterday wasn't from the sanding lubricant, it was from me. I have experienced sun stroke, and even under cover of a garage, overheating is still possible. I have no desire to spend a day in emerg while they pump me full of electrolytes to replace what I lost due to personal negligence.
Nick