Rust repair before paint, The quest for solid metal in the driver side Long - 73 narrow body/4 rebuild thread Options

[Montreal914]

Edit: I might as well make this my rebuild thread...

Original post; I got side tracked on my Microsquirt build as I have decided, after 11 years of ownership, to finally get my car painted to get her ready for her upcoming 50th birthday. (IMG:style_emoticons/default/smile.gif)
Knowing these endeavors can take a lot more time than initially planned, I hope to make it in time... (IMG:style_emoticons/default/wacko.gif)

Originally bahia red 73 1.7. The goal is a narrow body 2056 Microsquirt, VW Tornado red, 5 lugs conversion with 16" Fuchs.
Front: 914-4 A arms with rubber bushings, 911 3" pin struts, Bilstein inserts, Alfa Brembo, vented rotor, stock torsion bar, 19mm sway bar, turbo tie rods, and 19mm master cylinder.
Rear: Drilled hubs, 914 PMB stock calipers edit: 914-6 calipers replica, 914-6 solid rear rotors, 140lbs springs, stock sway bar, rubber bushings.

But before I get the pleasure of installing all of these beautiful fresh goodies, I need to tackle the not so fun stuff... (IMG:style_emoticons/default/headbang.gif)

I have already started fixing some of the rust issues and will share that progress in the near future but right now, I wanted to post some of the issues i have on the passenger side front fender. (IMG:style_emoticons/default/sad.gif) I have searched and read many of the builds here but I would like some inputs from the people who have gone through this mess.

I am trying to understand the construction of the rear part of the fender, more precisely the area joining the front cowling.

Below is a sketch of how I think it is made but i would like someone to confirm...



Having removed the seam sealer in the upper rear area, I have discovered "this" (IMG:style_emoticons/default/dry.gif) which is not really unusual, but clearly a pain to fix. I am not sure though what I am looking at. If my sketch is correct, I guess the inner rusted layer is from the fender rear bulkhead that actually becomes an inner layer on the rear upper point of the fender by the door and cowling junction.





I might be able to cut this from the underside preventing me from cutting the outer surface of the fender. But I would like to better understand what is happening at the junction to the body.
How many layers are there from the fender, one or two?
Is the metal peeling off at the joint to the body the metal from the bulkhead/inner layer, or is it the outer fender layer?

As a reference, this if the situation of the channel, surface rust, but how bad? Is there a way to better know without destroying? Maybe poke with a screwdriver? (IMG:style_emoticons/default/confused24.gif)



Comments appreciated (IMG:style_emoticons/default/smile.gif)

[Montreal914]

@Eric_Shea Thank you for the link. Very nice pictures and, as expected, beautiful restoration work! (IMG:style_emoticons/default/smilie_pokal.gif)

Time for a little update at my end. Before installing the new cowl repair piece I had to take care of the rusted corner in the inner fender area. I created a little patch that had many corner and struggled with very limited access to install it. Not the best work, but it will have to do... (IMG:style_emoticons/default/dry.gif) Then I prepped the area with weld through primer.



Repair piece ready for install




After a lot of trial fit and subtle grinding and filing of both the car and the repair piece, it was time to make the big step of installing the cowl repair piece. After a couple of tacks at the windshield area, I wanted to fit the trunk seal area.



Then checked the result from underneath and wasn't happy with how this was lining up... (IMG:style_emoticons/default/dry.gif) Time to cut and redo that.

Original attempt


Second try


Moving on to more tack welding


Making sure things are still lined up. Not perfect but I didn't think I had the ability to do better.


The front edge was a concern and this is where we can see that the reproduction part is not 100% perfect. I was able to raised it up with light taping from underneath but final body work will need to address that area.



Then, slowly fill the voids between the tack weld, one spot at a time... (IMG:style_emoticons/default/welder.gif)

Still have the back edge of the A pillar to complete but this is close to final. As a first attempt to venture into this kind of work I am happy with my accomplishment. Support here was key (IMG:style_emoticons/default/smilie_pokal.gif) @Cary . Hopefully the second part of this repair, fender side, will go well too.