i reworked mine ,i actually did not want the front area were battery, and charcoal canister went .i straightened and welded holes i did not want , sand blasted epoxied and used a fill primer blocked and reprimed and prep and refinished . the tire side i used a urethane stone guard before paint.The way I would approach it is to measure the current cutout on the original fender and add about a half inch to each edge. An easy way to do this is to take a piece of cardboard, hold it under the opening and trace it. Then, measure about a half inch beyond these edges and add some lines. Then lay this pattern in as close to the same position as possible cut this out of the donor fender. Now you have a part that has the same curves and bends as the original, but just a bit bigger. Now you can hold this up under the original fender cutout and move it around until it is in the exact correct position. Once there, you can with a metal scriber trace the opening exactly. Carefully trim this to size and it should be ready to tack weld into position for a trial. If good, then finish the weld by hitting a spot randomly to keep it cool until it is fully welded.
This process should work unless the cutout opening is really bent out of its original shape, which is possible if whoever cut it didn't care.
As far as using the rusted fender, I've seen worse used. I would blast it clean (be gentle but get all the rust off). Then if it only has random small holes you may be better off fixing it by filling the holes and epoxy priming. then move to a high build primer and block it smooth. It's a tough call for sure. If your original is really good other than the cutout, you are probably correct to try and fix it.
What boat did i miss and where did you say anything about repo fitting like crap?I guess you missed the boat, first of all, the reproduction inner fenders fit like crap. Secondly, this fender is a one year only, and only the first half of the production year piece. Very rare and valuable.
What boat did i miss and where did you say anything about repo fitting like crap?
You certainly come off like a jerk..