Welding Sheet Metal Help

badazz81z28

Veteran Member
May 4, 2001
21,918
Alabama
Might want to go so far as to call a local tool-machine shop for a welding reference. Those guys weld to micron level tolerance (laser weld if required), not that you need this but they can do it. These guys aren't cheap (~150-200 per hour) but if you want the best that's where to go.

As hard as this fender was to come by, I would pay $300-$500 to have done. Call me crazy!
 

badazz81z28

Veteran Member
May 4, 2001
21,918
Alabama
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So how to tackle this? Bigger cut?
 

70lt1z28

Veteran Member
Gold Member
Oct 3, 1999
4,766
Beavercreek, Ohio, USA
I don't see where in this case a bigger cut will help anything. There aren't any natural lines to cut to anywhere close. Hard to tell, but is there are reason not to use the other fender? The rust doesn't look too terrible on the new one.
 

badazz81z28

Veteran Member
May 4, 2001
21,918
Alabama
sandblast it and patch it..it'll at least fit back

Maybe I don't understand...why would I blast and patch the rusty one? That has rust pits all over. When I have this one I can patch?
 

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73Z L92

Veteran Member
Jan 25, 2011
474
Carlos, MN
After looking at the pics of the rusty inner fender I think the sand blaster would find many pin holes. I would patch the black inner fender. Can you use a piece off the rusty fender? Clean up the rust making sure it's sound, make a pattern and weld in.
 

badazz81z28

Veteran Member
May 4, 2001
21,918
Alabama
After looking at the pics of the rusty inner fender I think the sand blaster would find many pin holes. I would patch the black inner fender. Can you use a piece off the rusty fender? Clean up the rust making sure it's sound, make a pattern and weld in.

The majority of the inner fender probably would have little pin holes, at least look like the surface of the moon. What a shame, I know.
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