Don's 69 Charger Rust Belt restoration

[tan top]

 

[mopar4don]

Ok I left off with fixing the fender door brace.

[mopar4don]

Ok now for the really fun stuff!
The pass fender needs some patches made for the front and rear dog legs (front and rear of the wheel)
So I will start at the rear dog leg

[mopar4don]

So I looked at my junk fender collection for a patch (I have a few  ), and took the best I had.
Unfortunately the patch is going to need a patch (IT NEVER ENDS!) 

[mopar4don]

So I found some metal from a junk quarter panel that had the same basic shape AND it had a 90 bend!

[mopar4don]

After some welding

[mopar4don]

SO next I need to get the profile a bit closer (the profile along the edge of the door) so I made up some templates and worked in in

[mopar4don]

Working it in involved a shrinker...
I also used the inner fender support bracket to help get it into position.

[Baldwinvette77]

Not too many people can say they patched their patch panels! 

[Pat1973charger]

Looks good as usual. I am in the same boat. I have patched a lot of my patch and replacement panels haha

[Charger_Fan]

I see a spot where you could fit one more vice grip clamp in...

Nice work, you're making progress!

[mopar4don]

A little update....
Cut off the old rusted through area on the fender.

[mopar4don]

Here I got the new patch positioned using the inner brace to help

[mopar4don]

Once I was satisfied with the positioning of the patch I started welding

[mopar4don]

Here is a pic showing the seam welded and ground On the front and back side. Not real proud of my work as I am still getting sink marks around the weld. Even though I am planishing every weld dot.
Oh well needs a little bumping and filing.

[Bronzedodge]

Even though I am planishing every weld dot.

snip

Don, how are you planishing that spot?  By hand with a hammer and dolley or a power planishing hammer?

[charger chris]

Hello Don
  It was nice meeting you. Thank for working with me on the firewall.  I will put it back on the car where it was cut off. I am trying use all the he pull off of it.

[CDN72SE]

Very nice work, really admire stuff like that. 

[Stevearino]

Some folks have deep pockets that carry them through a resto. I don't think anyone would argue with me that you are working with deep commitment and talent.

[Charger_Fan]

Some folks have deep pockets that carry them through a resto. I don't think anyone would argue with me that you are working with deep commitment and talent.

Absolutely! 

[mopar4don]

Next I will be showing how I patched the lower front area of this fender.

[mopar4don]

I will form the entire lower area cutting it just above the body line (in this view) as shown by the blue line

[mopar4don]

I have another fender (from a 68 Charger) that is good in this area, so I will be using it as a reference to make templates for this patch.
I started by removing the inner structure from the nose of the fender.
I did this because I thought it would be in the way. And I may fix the 68 fender and sell it at some point.

pic2
This pic shows the area I will be reproducing (hopefully)

[mopar4don]

So to help with forming this patch panel, I will make a Flexible Shape Pattern or (FSP).
The FSP will be used to compare the patch that will be formed by hammer and shot bag. (more on this later)

I used 3/4 inch wide 3M reinforced tape like this

[mopar4don]

I started by covering the area with saran wrap. The tape will stick to the saran wrap and allow you to remove it.
Then I started laying the tape. (2 layers at approx 90 degrees to each other)